WO2016121762A1 - Application method, application device, and panel manufacturing method - Google Patents

Abstract

To provide a sealing material application method or the like capable of applying a sealing material with a uniform film thickness even in the cases where the shapes of a supporting base material and an end portion (side surface and front surface) of a film are not linear. The present invention is an application method for applying a sealing material 130 to a film end portion of a structure wherein a film 120 is bonded to a supporting base material 110. Prior to applying the sealing material 130, the position of the film end portion and the height of a film end portion front surface on the supporting base material 110 side and/or the height of a film end portion front surface on the film 120 side are detected, and corresponding to the film end portion position and the heights thus detected, the sealing material 130 is applied, while moving leading ends of first and second nozzles, such that a distance between the film end portion and a leading end of the first nozzle is maintained constant, and a distance between the film end portion front surface and a leading end of the second nozzle is maintained constant.

Description

Coating method, coating apparatus, and panel manufacturing method

The present invention relates to a coating method, a coating apparatus, and a panel manufacturing method.

In recent years, solar energy has attracted attention as an alternative energy to fossil fuels such as oil and natural gas. Solar energy is known as clean energy for the environment without fear of exhaustion.

As a power generation method using solar energy, for example, there is solar thermal power generation. Solar thermal power generation is a technology that converts sunlight, which is solar energy, into thermal energy, and generates power using this thermal energy. Generally, the energy density of sunlight is low, and in order to compensate for this, sunlight is collected by a mirror or lens and converted to thermal energy. Hereinafter, a device that collects sunlight is referred to as a light collecting device.

The light collector is exposed to ultraviolet rays from sunlight, heat, rain, and sandstorms. Therefore, conventionally, a glass mirror in which a colorless and transparent glass material with high environmental durability is used as a base material and a reflective film is formed on the back surface of the base material has been used for the light collecting device. However, such a glass mirror is easily damaged during transportation, and it is necessary to increase the strength of the gantry.

Therefore, instead of a glass mirror, a solar reflective panel having a resin reflective film (film mirror) has been developed (for example, Patent Document 1). The solar reflective panel of Patent Document 1 is used with a resin reflective film bonded onto a support substrate. And the resin-made reflective film is provided with a plurality of layers having different functions such as a silver reflective layer for reflecting sunlight and an outermost layer made of a material having a metalloxane skeleton on the resin base material. Yes.

In general, a reflective film of the same size as the support base material is bonded onto the support base material, and an end portion is provided with a sealing material to prevent intrusion of oxygen, water vapor, hydrogen sulfide, or the like. Applied.

International Publication No. 2011/096309

However, if the shape of the end portion (side surface or surface) of the supporting base material or the reflective film is not linear, there is a possibility that the thickness of the sealing material may be uneven. For example, if there are curves (swells, irregularities, distortions, etc.) on the side surfaces and surfaces of the support substrate and the reflective film, there may be places where the sealing material is not applied partially.

The present invention has been made in view of the above circumstances. That is, an object of the present invention is to provide a sealing material coating method and the like capable of uniform coating even when the shape of the support substrate and the end portions (side surfaces and surface) of the film is not linear. To do.

(1) A coating method in which a sealing material is applied to a film end of a structure in which a film is bonded to a supporting substrate, and (a) prior to the application of the sealing material, the position of the film end Detecting a height of at least one surface of the film end portion on the side of the support base and the film side; and (b) maintaining a constant gap between the film end portion and the tip of the first nozzle. The step of applying the sealing material while moving the tip of the first nozzle according to the position of the film end detected in the step (a), and (c) the film end The tip of the second nozzle is moved while moving the tip of the second nozzle according to the height of the surface detected in step (a) so that the gap between the surface of the part and the tip of the second nozzle is kept constant. Apply sealant Tsu coating method has a flop, the.

(2) The coating method according to (1), wherein in step (a), the position of the film end and the height of the surface are detected using a displacement sensor or a camera.

(3) In the step (b), the tip of the first nozzle is moved by driving the first motor, and in the step (c), the second motor is driven to drive the second nozzle. The coating method according to (1) or (2), wherein the tip is moved.

(4) In the step (b), the structure is transported relatively to the first nozzle, and after the start point of the structure is detected in the step (a), the start point is the first nozzle. When the position reaches the position, control for moving the tip of the first nozzle is started. In the step (c), the structure is conveyed relative to the second nozzle, and the step (a) In (1) to (3), the control for moving the tip of the second nozzle is started when the start point of the structure reaches the position of the second nozzle after the start point of the structure is detected. The application | coating method in any one.

(5) In the step (b), the structure is transported relative to the first nozzle, and after the end point of the structure is detected in the step (a), the end point is the first nozzle. When the position reaches the position, the control of moving the tip of the first nozzle is terminated, and in the step (c), the structure is conveyed relative to the second nozzle, and the step (a) In the above (1) to (4), after the end point of the structure is detected, the control of moving the tip of the second nozzle is started when the end point reaches the position of the second nozzle. The application | coating method in any one.

(6) The coating according to any one of (1) to (5), wherein the positional accuracy of the tips of the first nozzle and the second nozzle is 1/3 or less of the coating thickness of the sealing material. Method.

(7) The coating method according to any one of (1) to (6) above, wherein the length of the sealing material applied to the film end is 1 m or more.

(8) The coating method according to any one of (1) to (7), wherein a conveyance speed of the structure with respect to the first nozzle and the second nozzle is 5 m / min or more.

(9) The film is a reflective film for reflecting sunlight, and the structure having the sealing material applied to the end portion is a solar reflective panel. ).

(10) The first nozzle and the second nozzle that are integrally formed are used for applying the sealing material in the step (b) and the step (c). (1) to (9) The coating method according to any one of the above.

(11) A coating apparatus that applies the sealing material by the coating method according to any one of (1) to (10) above.

(12) (a) A film is bonded to the supporting substrate in the shape of the supporting substrate, and (b) the film end of the structure formed by the bonding in the step (a). Applying a sealing material, and in the step (b), the sealing material is applied by the coating method according to any one of the above (1) to (10).

According to the present invention, the sealing material is applied while moving the tips of the first nozzle and the second nozzle in accordance with the curvature (swell, unevenness, distortion, etc.) of the support base or the end of the film. Thereby, even when there is a curve at the end of the support base or the film, it is possible to apply the sealing material with a uniform film thickness. As a result, reduction of the sealing effect can be prevented. Further, it is possible to apply a thinner sealing material, and it can be expected to save the sealing material and improve productivity by shortening the curing time of the sealing material.

Further objects, features, and characteristics of the present invention will become apparent by referring to the preferred embodiments illustrated in the following description and the accompanying drawings.

It is a schematic perspective view of the solar reflective panel which concerns on this embodiment. FIG. 2 is a schematic cross-sectional view taken along line AA in FIG. It is a schematic sectional drawing which shows the layer structure of a reflective film. It is a figure for demonstrating the detailed shape of a sealing material. It is a schematic block diagram of a coating device. It is a schematic external view of a nozzle. FIG. 7 is a schematic cross-sectional view of the nozzle of FIG. 6 when viewed along line 7A-7A. FIG. 8 is a schematic cross-sectional view of the nozzle taken along line 8A-8A in FIG. FIG. 8 is an enlarged view of FIG. 7. It is an enlarged view of FIG. FIG. 8 is a schematic cross-sectional view of the nozzle taken along line 11A-11A in FIGS. It is an enlarged view of FIG. It is a flowchart which shows the procedure of the coating process performed in a coating device. It is a figure which shows the shape of the sealing material of the panel for sunlight reflection produced in Example 3. FIG. It is a figure which shows the front-end | tip part (discharge port) of the nozzle used at the time of preparation of the solar reflective panel of Example 3. FIG. It is a figure which shows the evaluation result of coating quality 1 and 2. FIG. It is a figure which shows the modification of the shape of a sealing material.

Hereinafter, an embodiment of the present invention will be described with reference to the accompanying drawings. In the description of the drawings, the same elements are denoted by the same reference numerals, and redundant description is omitted. In addition, the dimensional ratios in the drawings are exaggerated for convenience of explanation, and may be different from the actual ratios.

<Solar reflection panel 100>
FIG. 1 is a schematic perspective view of a sunlight reflecting panel according to the present embodiment. FIG. 2 is a schematic sectional view taken along line AA in FIG. FIG. 3 is a schematic cross-sectional view showing the layer structure of the reflective film. FIG. 4 is a view for explaining the detailed shape of the sealing material. Hereinafter, the solar reflective panel 100 according to the present embodiment will be described with reference to FIGS.

As shown in FIGS. 1 and 2, the solar reflective panel 100 includes a support base 110, a reflective film 120, and a sealing material 130. The solar reflective panel 100 is formed by applying a sealing material 130 to an end of a structure in which a reflective film 120 is bonded to a support base 110. In addition, the size of one solar reflective panel 100 is not particularly limited, but is, for example, 2 m long × 4 m wide.

(1) Support base material 110
The support substrate 110 is a substrate for supporting the reflective film 120, and is preferably a self-supporting support substrate. As the support base 110, for example, aluminum, aluminum plating, aluminum-based alloy plating, steel, copper, copper plating, tin plating, chromium plating, stainless steel, or the like can be used. Among these, it is particularly preferable to use a plated steel plate, a stainless steel plate, an aluminum plate, or the like having good corrosion resistance. In addition, examples of the shape of the support substrate 110 include a film shape, a sheet shape, a flat plate shape, a curved plate shape, a hemispherical shape, and a bowl shape. Note that the support substrate 110 is not limited to the above-described materials and shapes as long as the support substrate 110 has sufficient rigidity to support the reflection film 120 when the edge portion of the reflection film 120 is supported. For example, a material such as glass, quartz, or resin may be used as the support base 110. Among these, as the resin, acrylic resin, polycarbonate, polyarylate, polyethylene naphthalate, polyethylene terephthalate (PET), fluorine resin, and the like can be used. Or a resin film or sheet kneaded with the above resin and titanium oxide, silica, aluminum powder, copper powder, etc., or a resin film or sheet coated with a resin kneaded with these or subjected to surface treatment such as metal deposition May be used as a support substrate. Further, the thickness of the support substrate 110 may be changed according to the type of material used for the support substrate 110. In general, the thickness of the support substrate 110 is preferably in the range of 0.1 mm to 5 mm, and more preferably in the range of 0.3 mm to 2 mm.

Or, as a self-supporting support base material, one having a pair of metal flat plates and an intermediate layer interposed between the metal flat plates (type A) or one made of a resin material having a hollow structure (type B) is used. May be. For these specific configurations, self-supporting substrates A and B described in WO 11/162154 pamphlet or US Patent Application Publication No. 2013/0114155 can be employed.

(2) Reflective film 120
The reflection film 120 is a resin film that reflects light (for example, sunlight) from a light source. As shown in FIGS. 1 and 2, the reflective film 120 is bonded in the shape of the support base 110.

Further, as shown in FIG. 3, the reflection film 120 is composed of a plurality of layers having different functions, and has at least a reflection layer 121 for reflecting light. At least one protective layer is disposed on the light incident side of the reflective layer 121. As a preferable layer configuration of the reflective film 120 according to this embodiment, a corrosion prevention layer 122, an ultraviolet absorption layer 123, a gas barrier layer 124, and a hard coat layer 125 are sequentially laminated on the light incident side of the reflective layer 121. Further, at least one support layer (for example, a resin support layer 127 described later) is disposed on the support base 110 side (the side opposite to the light incident side) of the reflective layer 121. As a preferred layer configuration of the reflective film 120 according to this embodiment, an anchor layer 126, a resin support layer 127, and an adhesive layer 128 are sequentially laminated on the support base 110 side of the reflective layer 121. Note that a release layer (not shown) for covering the adhesive layer 128 may be provided until the reflective film 120 is bonded to the support substrate 110.

Hereinafter, each of the layers 121 to 128 will be described in detail.

(2-1) Reflective layer 121
The reflective layer 121 is a layer made of a metal having a function of reflecting light (for example, sunlight) from a light source. The surface reflectance of the reflective layer 121 is preferably 80% or more, and more preferably 90% or more.

The reflective layer 121 is formed of a material containing any element selected from aluminum, silver, chromium, copper, nickel, titanium, magnesium, rhodium, platinum, palladium, tin, gallium, indium, bismuth, and gold. Is preferred. In particular, it is preferable that aluminum or silver is the main component from the viewpoint of reflectivity, and two or more layers of such metal thin films may be formed. As the reflective layer 121 of this embodiment, a silver reflective layer containing silver as a main component is used.

The thickness of the reflective layer 121 is preferably in the range of 10 nm to 200 nm, more preferably 30 nm to 150 nm, from the viewpoint of reflectance and the like. It is preferable that the thickness of the reflective layer 121 be greater than 10 nm because the film thickness is sufficient and light is not transmitted, and the reflectance in the visible light region of the reflective film 120 can be sufficiently secured. Further, the reflectance increases in proportion to the film thickness up to about 200 nm, but it does not depend on the film thickness over 200 nm.

The surface roughness of the reflective layer 121 is in the range of 0.01 μm to 0.1 μm, and preferably in the range of 0.02 μm to 0.07 μm. Since the surface roughness of the reflective layer 121 is 0.01 μm or more, even when the roll-to-roll method of continuously forming the film in the production stage of the reflective film 120 is used, the reflective layer 121 is adjacent to the incident light side. The sticking of the layer (corrosion prevention layer 122 in this embodiment) can be prevented.

As a method for forming the reflective layer, either a wet method or a dry method can be used. The wet method is a general term for a plating method, and is a method of forming a film by depositing a metal from a solution. Specific examples include silver mirror reaction. On the other hand, the dry method is a general term for a vacuum film-forming method. Specific examples include a resistance heating vacuum deposition method, an electron beam heating vacuum deposition method, an ion plating method, and an ion beam assisted vacuum deposition method. And sputtering method. In particular, a vapor deposition method capable of a roll-to-roll method for continuously forming a film is preferably used in the present invention. For example, in the manufacturing method of the film mirror for solar thermal power generation, it is preferable that it is a manufacturing method which forms a light reflection layer by silver vapor deposition (especially vacuum vapor deposition).

(2-2) Corrosion prevention layer 122
The corrosion prevention layer 122 is provided to prevent the reflection layer 121 from being corroded. Therefore, the corrosion prevention layer 122 is preferably provided adjacent to the reflective layer 121. In particular, when the reflective layer 121 contains a metal (for example, silver), it is preferable to provide the corrosion prevention layer 122. In particular, the corrosion prevention layer 122 is more preferably adjacent to the light incident side of the reflective layer 121. Further, the corrosion prevention layer 122 may be adjacent to both sides of the reflective layer 121.

The corrosion prevention layer 122 contains a corrosion inhibitor. As the corrosion inhibitor, broadly, a corrosion inhibitor having an adsorptive group for metals, particularly silver, and a corrosion inhibitor having an antioxidant ability (also referred to as an antioxidant) are preferably used. The corrosion prevention layer 122 preferably contains at least one of a corrosion inhibitor and an antioxidant having an adsorbing group for metal, particularly silver. Here, “corrosion” refers to a phenomenon in which a metal (silver) is chemically or electrochemically eroded or deteriorated by an environmental material surrounding it (see JIS Z0103-2004).

Resin (for example, acrylic resin) can be used for the corrosion prevention layer 122 as a binder for holding the corrosion inhibitor. More specifically, the resin and the corrosion inhibitor used for the corrosion prevention layer 122 are not particularly limited, but for example, a WO 2012/165460 pamphlet (particularly, paragraph “0079”- Materials similar to those described in known literature such as “0095”) can be used. The optimum content of the corrosion inhibitor varies depending on the compound used, but generally it is preferably in the range of 0.1 g / m ² or more and 1.0 g / m ² or less.

Further, the corrosion prevention layer 122 preferably contains an ultraviolet absorber. Thereby, the lower layer than the corrosion prevention layer 122 can be protected more effectively. For this reason, the durability of the reflective film 120 can be further improved. Here, the ultraviolet absorber is not particularly limited. For example, organic ultraviolet absorbers such as thiazolidone, benzotriazole, acrylonitrile, benzophenone, aminobutadiene, triazine, phenyl salicylate, and benzoate Alternatively, there are fine powder type ultraviolet blocking agents such as cerium oxide and magnesium oxide, and inorganic ultraviolet absorbing agents such as titanium oxide, zinc oxide and iron oxide. Of these, organic ultraviolet absorbers and inorganic ultraviolet absorbers are preferred, and triazine ultraviolet absorbers and inorganic ultraviolet absorbers are more preferred. That is, the ultraviolet absorber is preferably a triazine ultraviolet absorber or an inorganic ultraviolet absorber.

The thickness of the corrosion prevention layer 122 is preferably 30 nm or more and 1 μm or less.

The corrosion prevention layer can be formed by applying and coating these resin materials (binders) on the light reflection layer or the like.

(2-3) UV absorbing layer 123
The ultraviolet absorption layer 123 is provided to absorb ultraviolet rays incident on the reflection layer 121 for the purpose of preventing the reflection film 120 from being deteriorated by sunlight or ultraviolet rays. The ultraviolet absorption layer 123 is preferably provided on the light incident side with respect to the corrosion prevention layer 122.

As the ultraviolet absorbing layer 123, for example, various resins such as polycarbonate and polyethylene terephthalate can be used. In particular, it is preferable to use a polyester film such as polyethylene terephthalate or an acrylic film. Among these, an acrylic film highly resistant to ultraviolet rays is particularly preferable.

The ultraviolet absorbing layer 123 contains an ultraviolet absorber. For example, the ultraviolet absorption layer 123 contains a triazine compound as an ultraviolet absorber. In addition, benzophenone-based, benzotriazole-based, phenyl salicylate-based as organic types, and titanium oxide, zinc oxide, cerium oxide, iron oxide, and the like may further be included as inorganic types.

Further, when an acrylic layer (a methacrylic resin or the like is a main component) is used as the ultraviolet absorbing layer 123, fine particles of a plasticizer may be included in order to make the layer soft and not easily damaged. Preferable examples of the plasticizer fine particles include butyl rubber and butyl acrylate fine particles.

Further, the thickness of the ultraviolet absorbing layer 123 is preferably 30 nm or more and 200 μm or less, and more preferably 50 nm or more and 5 μm or less.

(2-4) Gas barrier layer 124
The gas barrier layer 124 is provided in order to prevent deterioration of humidity, in particular, deterioration of the resin base material (resin support layer 127) and each component layer supported by the resin base material due to high humidity. The gas barrier layer 124 is preferably provided on the light incident side from the reflective layer 121. The gas barrier layer 124 may further have functions and applications other than the deterioration prevention function.

As the moisture resistance of the gas barrier layer 124, the water vapor permeability at 40 ° C. and 90% RH is preferably 1 g / m ² · day or less, more preferably 0.5 g / m ² · day or less, and still more preferably Is 0.2 g / m ² · day or less.

The oxygen permeability of the gas barrier layer 124 is preferably 0.6 ml / m ² · day · atm or less under the conditions of a measurement temperature of 23 ° C. and a humidity of 90% RH.

The gas barrier layer 124 is formed by subjecting a coating film such as a silazane compound or a siloxane compound which is an inorganic oxide precursor to a conversion treatment (oxidation treatment).

The thickness of the gas barrier layer 124 is preferably 30 nm or more and 2000 nm or less, more preferably 40 nm or more and 500 nm or less, and particularly preferably 40 nm or more and 300 nm or less.

The material used for the gas barrier layer 124 and the method for forming the gas barrier layer 124 are not particularly limited. For example, it is described in known documents such as WO 2012/165460 pamphlet (particularly, paragraphs “0188” to “0209”). Similar materials and methods as described can be used.

(2-5) Hard coat layer 125
The hard coat layer 125 is provided to prevent the surface of the reflective film 120 from being scratched or contaminated. Therefore, the hard coat layer 125 is preferably provided on the outermost layer on the light incident side. However, an antifouling layer (not shown) having water repellency may be provided further outside (light incident side) than the hard coat layer 125.

The hard coat layer 125 can be composed of any material as long as transparency, weather resistance, hardness, mechanical strength, and the like are obtained. For example, the hard coat layer 125 is made of an acrylic resin, a urethane resin, a melamine resin, an epoxy resin, an organic silicate compound, a silicone resin, or the like. In particular, silicone resins and acrylic resins are preferable in terms of hardness and durability. Furthermore, an active energy ray-curable acrylic resin or a thermosetting acrylic resin is preferable in terms of curability, flexibility, and productivity. Alternatively, metalloxane (organic silicate compound, silicone resin) is preferably used in terms of high surface protection and weather resistance. That is, the hard coat layer is preferably a metalloxane-based hard coat layer.

Further, the thickness of the hard coat layer 125 is preferably 0.05 μm or more and 10 μm or less from the viewpoint of preventing the reflection film 120 from being warped while obtaining sufficient scratch resistance. More preferably, it is 1 μm or more and 10 μm or less.

(2-6) Anchor layer 126
The anchor layer 126 is made of resin, and is provided to form a favorable reflective layer 121 on the resin support layer 127 (light incident side). Therefore, the anchor layer 126 has an adhesion property that allows the resin support layer 127 and the reflective layer 121 to adhere to each other, heat resistance that can withstand heat when the reflective layer 121 is formed by a vacuum deposition method, and the high reflective performance of the reflective layer 121. It is preferable to have smoothness for drawing out.

The resin used for the anchor layer 126 is not particularly limited as long as it satisfies the above conditions of adhesiveness, heat resistance, and smoothness. Polyester resin, acrylic resin, melamine resin, epoxy resin, polyamide Resin, vinyl chloride resin and the like. In particular, from the viewpoint of weather resistance, a mixed resin of a polyester resin and a melamine resin, or a mixed resin of a polyester resin and an acrylic resin is preferable, and a thermosetting resin in which a curing agent such as isocyanate is further mixed is preferable. More preferred.

Further, the thickness of the anchor layer 126 is preferably 0.01 μm or more and 3 μm or less, and more preferably 0.1 μm or more and 2 μm or less. If the thickness is within this range, the unevenness on the surface of the resin support layer 127 can be covered, and good smoothness and adhesion can be obtained. In addition, if the anchor layer 126 has sufficient hardness, as a result, the reflectance of the reflective layer 121 can be increased. The anchor layer 126 preferably contains a corrosion inhibitor used for the corrosion prevention layer 122.

Further, the material used for the anchor layer (resin material) and the method for forming the anchor layer are not particularly limited. For example, known materials such as WO 2012/165460 pamphlet (particularly, paragraphs “0209” to “0212”) Materials and methods similar to those described in the literature can be used.

(2-7) Resin support layer 127
The resin support layer 127 is used to form a (reflective) layer. The material of the resin support layer 127 is not particularly limited as long as the (reflection) layer can be formed (film formation), and various resin films can be used. For example, it is preferable to use a polyester film such as polyethylene terephthalate or an acrylic film.

The thickness of the resin support layer 127 is preferably set to an appropriate thickness according to the type and purpose of the resin. For example, it may be in the range of 10 μm to 300 μm, preferably 20 μm to 200 μm, and more preferably 30 μm to 100 μm.

(2-8) Adhesive layer 128
The adhesive layer 128 has adhesiveness so that the reflective film 120 can be bonded to the support substrate 110. The adhesive layer 128 is provided on the surface (back surface) opposite to the surface on which the reflective layer 121 of the resin support layer 127 is formed. The material of the adhesive layer 128 is not particularly limited, and for example, a dry laminating agent, a wet laminating agent, an adhesive, a heat seal agent, a hot melt agent, or the like is used.

The thickness of the adhesive layer 128 is preferably in the range of 1 μm or more and 100 μm or less from the viewpoint of the adhesive effect, the drying speed, and the like.

If necessary, an ultraviolet absorbing layer 123, a gas barrier layer 124, an adhesive layer, and the like may be provided between the layers. Further, a release layer, an antifouling layer, or the like may be provided on the light incident side of the hard coat layer 125.

The total thickness of the reflective film 120 of this embodiment is not particularly limited, but is preferably 75 to 300 μm, more preferably 90 to 250 μm, and still more preferably 100 to 250 μm from the viewpoints of prevention of bending, regular reflectance, handling properties, and the like. It is. In addition, the center line average roughness (Ra) of the outermost surface layer on the light incident side of the reflection film is preferably 3 nm or more and 20 nm or less from the viewpoint of preventing scattering of the reflected light and increasing the light collection efficiency.

(3) Sealing material 130
The sealing material 130 is arrange | positioned along the outer periphery of the support base material 110 and the reflective film 120 so that the side surface (edge part) of the support base material 110 and the reflective film 120 may not be exposed. As shown in FIGS. 1 and 2, the sealing material 130 is not only on the side surfaces of the support substrate 110 and the reflective film 120 but also on the exposed surface of the reflective film 120 (that is, the surface on the light incident side). Top) or on the exposed surface of the support substrate 110 (ie, on the surface opposite the light incident). By covering the side surfaces of the support substrate 110 and the reflection film 120, dust, dust, oxygen, water vapor, hydrogen sulfide, or the like can be prevented from entering from the side surfaces of the support substrate 110 and the reflection film 120. . At the same time, the sealing material 130 can be prevented from being peeled by being integrally disposed on the exposed surface of the reflective film 120 or on the exposed surface of the support substrate 110. As a result, the deterioration of the reflective film 120 is suppressed. For example, it becomes difficult for the reflective film 120 to peel off from the support substrate 110, and when the reflective layer 121 is a metal, corrosion of the reflective layer 121 can be suppressed or prevented.

The material of the sealing material 130 is not particularly limited, but from the viewpoint of ease of formation, gas barrier properties, durability, and the like, a curable resin such as a thermosetting resin, an active energy ray curable resin, a heat It can be suitably selected from plastic resins and the like.

Examples of the thermosetting resin include silicone resin, urethane resin, epoxy resin, melamine resin, unsaturated polyester resin, and phenol resin.

Examples of the active energy ray curable resin include epoxy acrylate resin, urethane acrylate resin, and polyester acrylate resin.

Examples of the thermoplastic resin include acrylic resin, polyethylene resin, and polypropylene resin.

More specifically, as the sealing material 130, a paste-like silicone sealant (KE45-G manufactured by Shin-Etsu Silicone Co., Ltd.), an epoxy resin having a viscosity of 10 Pa · s (2081D manufactured by ThreeBond Co., Ltd.), and an acrylic resin having a viscosity of 13 Pa · s. (3017D manufactured by Three Bond Co., Ltd.), a urethane resin having a viscosity of 300 Pa · s or more and 600 Pa · s or less at 25 ° C. (Hibrene XLL-6051A manufactured by MC Industrial Co., Ltd.) can be used.

Next, the shape of the sealing material 130 will be described in detail.

As shown in FIG. 4, the sealing material 130 preferably has a thickness T1 of 0 mm <T1 ≦ 0.5 mm on the side surfaces of the support base 110 and the reflective film 120. In this way, by restricting the film thickness T1 of the sealing material 130, the usage amount of the sealing material 130 can be suppressed to the minimum necessary on the side surface portions of the support base 110 and the reflective film 120, and the manufacturing is performed. Cost can be reduced.

Moreover, as shown in FIG. 4, the sealing material 130 has a thickness T2 of 0 mm <T2 ≦ 0.5 mm and a coating width W of 0.5 mm ≦ W ≦ 2.0 mm on the reflective film 120. preferable. As described above, since the film thickness T <b> 2 of the sealing material 130 is regulated, the height of the step formed between the surface of the reflective film 120 and the sealing material 130 can be relatively low. As a result, while having resistance to high-pressure cleaning and brush cleaning, it is difficult for dust and dirt to accumulate on the stepped portion, and a reduction in the reflectance of the reflective film 120 can be suppressed. Furthermore, by restricting the coating width W of the sealing material 130, the reflective area of the reflective film 120 can be maximized within a range that does not impair the sealing function as the sealing material 130, and the reflectance of the reflective film 120 is reduced. Can be kept to a minimum. Thereby, the solar reflective panel 100 with high electric power generation efficiency is obtained. In addition, since the amount of the sealing material 130 used can be minimized, the manufacturing cost can be reduced.

In the example shown in FIG. 4, the sealing material 130 is not applied to the back surface of the sunlight reflecting panel 100 (that is, the surface opposite to the light incident side). Therefore, the solar reflective panel 100 can be adhered to a holding base material (for example, a bowl-shaped base material) for holding the solar reflective panel 100 in a predetermined position and orientation without any gaps. As a result, the reflection direction of sunlight is not disturbed, and the power generation efficiency can be improved. In addition, the solar reflective panel 100 is not easily peeled off from the holding substrate, and the solar reflective panel 100 can be used for a long period of time without being replaced. Further, immediately after application of the sealing material 130, it is necessary to dry the sealing material 130, but a special method for holding the solar reflective panel 100 so that the sealing material 130 does not contact anywhere. No equipment is required.

Although not shown in FIG. 4, when the sealing material 130 is provided on the support base 110 side, the entire area of the reflective film 120 can be effectively utilized without reducing the reflective area of the reflective film 120. When the solar reflective panel 100 is attached to a holding base material (for example, a bowl-shaped base material) for holding the solar reflective panel 100 in a predetermined position or orientation, the holding base material is more than the solar reflective panel 100. By making it small, the generation of a gap due to the thickness of the sealing material 130 provided on the back surface side can be prevented, the sunlight reflection direction is not disturbed, and the power generation efficiency can be improved.

Note that the reflective film 120 may be provided with a layer other than the above-described layers 121 to 128 (for example, an antistatic layer) or a part of the layers (for example, the ultraviolet absorbing layer 123, the gas barrier layer 124, etc.). May be omitted. Further, the stacking order of the layers 121 to 128 is not limited to the above example, and the stacking order of some layers may be changed.

<Coating device 150>
Next, the coating apparatus 150 that applies the sealing material 130 to the support base 110 and the reflective film 120 will be described.

FIG. 5 is a schematic configuration diagram of the coating apparatus.

The coating device 150 includes a tank 151, a discharge valve 152, a nozzle 153, an LM guide 154, a movable stage 155, a transport mechanism (not shown), first and second motors 156a, b, Measuring devices 157a, b. The coating device 150 includes a detection device 161, a control device 162, a coating control device 163, a monitor 164, and first and second motor controllers 165a and 165b.

(1) Tank 151
The tank 151 stores a paste-like sealing material 130.

(2) Discharge valve 152
The discharge valve 152 supplies the paste-like sealing material 130 stored in the tank 151 to the nozzle 153. The discharge valve 152 can adjust the discharge pressure of the sealing material 130 to the nozzle 153 by opening and closing the supply valve of the sealing material 130 based on an instruction from the application control device 163.

(3) Nozzle 153
The nozzle 153 applies the sealing material 130 supplied from the tank 151 simultaneously and directly from the side surfaces of the support substrate 110 and the reflection film 120 over the surface of the reflection film 120. The nozzle 153 is a nozzle that employs, for example, an extrusion method (extrusion method). Details of the nozzle 153 will be described later.

(4) LM (linear motion) guide 154
The LM guide 154 has a guide mechanism that allows the nozzle 153 to slide in a direction (arrow A in the drawing) perpendicular to the conveyance direction of the structure when a first motor 156a described later is driven. By sliding the nozzle 153 along the LM guide 154, the tip of the first nozzle (first front lip 211a and first back lip 211b described later) (first back lip 211b described later) with respect to the side surface of the structure. Can be moved closer or further away.

(5) Movable stage 155
The movable stage 155 moves the nozzle 153 in the vertical direction (arrow B shown in the drawing) when a second motor 156b described later is driven. By moving the nozzle 153 in the vertical direction, the tip (second back lip 212b described later) of the second nozzle (second front lip 212a and second back lip 212b described later) approaches the surface of the structure. You can keep away.

(6) Conveying mechanism The conveying mechanism applies an object to be applied (that is, a structure in which the reflective film 120 is bonded to the support substrate 110) placed on a predetermined base just below the discharge port of the nozzle 153. Transport in the direction. For example, the transport mechanism transports the structure by moving a transport table on which the application object is placed or fixed.

(7) First motor 156a
The first motor 156a moves the nozzle 153 in a direction perpendicular to the conveyance direction of the structure (arrow A in the drawing). In other words, the first motor 156a can move the nozzle 153 closer to or away from the side surface of the structure. For example, the first motor 156a is realized by a stepping motor or the like. In addition, it is preferable that the position accuracy of the front-end | tip of the 1st nozzle moved by the 1st motor 156a is 1/3 or less of the coating film thickness (T1 mentioned later) of the sealing material 130. FIG.

(8) Second motor 156b
The second motor 156b moves the nozzle 153 in the vertical direction (arrow B shown in the figure). In other words, the second motor 156b can move the nozzle 153 closer to or away from the surface of the structure. For example, the second motor 156b is realized by a stepping motor or the like. Note that the positional accuracy of the tip of the second nozzle moved by the second motor 156b is preferably 1/3 or less of the coating thickness (T2 described later) of the sealing material 130.

(9) First measuring device 157a
The 1st measuring device 157a measures the position of the direction perpendicular | vertical with respect to the conveyance direction of the structure of the film edge part of the structure in which the reflective film 120 was bonded by the support base material 110. FIG. For example, the first measuring device 157a is an imaging device such as a camera. The first measuring device 157a captures the film edge, outputs the obtained image to the detection device 161, and detects the position of the film edge by performing image processing in the detection device 161. However, the present invention is not limited thereto, and a sensor for EPC (registered trademark, edge position control) or a sensor such as a laser may be used as the first measuring device 157a.

(10) Second measuring device 157b
The second measuring device 157b measures the height of the surface (however, the end portion) of the structure in which the reflective film 120 is bonded to the support base 110. Here, the surface of the structure includes at least one of the surface on the support base 110 side and the surface on the reflective film 120 side. For example, the second measuring device 157b is a non-contact type laser displacement meter. The second measuring device 157b measures the time from irradiating the surface of the structure with the laser light until receiving the reflected laser light, and sends the measurement result (time signal or distance signal) to the detecting device 161. Output. However, the second measuring device 157b is not limited to this, and an imaging device such as a camera, a contact type micro gauge, or the like may be used.

(11) Detection device 161
Prior to the application of the sealing material 130, the detection device 161 controls the first measurement device 157a and the second measurement device 157b to determine the position of the film end in the direction perpendicular to the conveyance direction of the structure and the structure. The height of the surface of the object (at least one of the surfaces of the support base 110 and the reflection film 120) is detected.

Specifically, the detection device 161 notifies the first measurement device 157a of a predetermined instruction to measure the position of the film end in the direction perpendicular to the conveyance direction of the structure, and the measurement Get the result. For example, when the first measurement device 157a is an imaging device such as a camera, the detection device 161 acquires an image captured by the first measurement device 157a. The detection device 161 detects the position of the film end of the structure from the acquired image by performing image processing, and transmits the amount of deviation from the reference position to the control device 162. However, as the reference position, the position of the nozzle when applying to a reference structure installed at an appropriate position is registered in advance.

Also, the detection device 161 notifies the second measurement device 157b of a predetermined instruction, thereby measuring the height of the surface of the structure and acquiring the measurement result. For example, when the second measurement device 157b is a laser displacement meter, the detection device 161 acquires a time signal or a distance signal measured by the second measurement device 157b. The detection device 161 detects the height of the surface of the structure from the acquired time signal or distance signal, and transmits a deviation amount from the reference height to the control device 162. However, as the reference height, the height of the nozzle when applying to a reference structure installed at an appropriate position is registered in advance.

The detection device 161 is realized by, for example, an image processing device, a displacement sensor controller unit, or a general computer.

Further, the detection device 161 may be used separately for the first measurement device 157a and the second measurement device 157b.

(12) Control device 162
The control device 162 detects the film end of the structure detected by the detection device 161 so that the gap between the film end of the structure and the tip of the first nozzle (first back lip 211b described later) is kept constant. The tip of the first nozzle is moved according to the position of the part. Specifically, the control device 162 gives a first instruction to drive the first motor 156a so that the tip of the first nozzle moves by the amount of deviation from the reference position transmitted from the detection device 161. Output to the motor controller 165a.

In addition, the control device 162 detects the surface of the structure detected by the detection device 161 so that the gap between the surface of the structure and the tip of the second nozzle (second back lip 212b described later) is kept constant. The tip of the second nozzle is moved according to the height. Specifically, the control device 162 gives an instruction to drive the second motor 156b so that the tip of the second nozzle moves by the amount of deviation from the reference height transmitted from the detection device 161. 2 Outputs to motor controller 165b.

Note that the control device 162 is realized by, for example, a programmable logic controller or a general computer.

Further, the control device 162 may be used separately for the first measuring device 157a and the second measuring device 157b.

(13) Application controller 163
The application control device 163 controls the discharge valve 152 to apply the sealing material 130 to the film end and the surface of the structure. For example, the application control device 163 outputs an instruction to open the discharge valve 152 when the application of the sealing material 130 is started, and closes the discharge valve 152 when the application of the sealing material 130 is finished. Is output.

The application control device 163 is realized by, for example, a general application controller (dispenser).

(14) Monitor 164
The monitor 164 displays an image that allows the user to confirm the application state of the sealing material 130. For example, when the first measuring device 157a is an imaging device such as a camera, the monitor 164 displays an image captured by the first measuring device 157a. The monitor 164 is realized by a liquid crystal display or the like.

(15) First motor controller 165a
The first motor controller 165a drives the first motor 156a based on an instruction from the control device 162. For example, when the first motor 156a is a stepping motor, the first motor controller 165a sends a necessary pulse signal to the first motor according to the distance at which the nozzle 153 is desired to move in a direction perpendicular to the conveyance direction of the structure. To 156a.

(16) Second motor controller 165b
The second motor controller 165b drives the second motor 156b based on an instruction from the control device 162. For example, when the second motor 156b is a stepping motor, the second motor controller 165b supplies a necessary pulse signal to the second motor 156b according to the distance at which the nozzle 153 is to be moved in the vertical direction.

<Nozzle 153>
Next, the nozzle 153 attached to the coating apparatus 150 will be described in detail.

FIG. 6 is a schematic external view of the nozzle.

(A) Overall Configuration As shown in FIG. 6, the nozzle 153 includes an upper block 210, a plate 211, a middle block 212, and a lower block 213. The lower block 213, the plate 211, the middle block 212, and the upper block 210 are stacked in this order. The plate 211 and the middle block 212 are sandwiched between the upper block 210 and the lower block 213 and fastened by screws (not shown).

The upper block 210 has an inlet 214 for injecting the sealing material 130 from the tank 151.

The plate 211 and the middle block 212 are arranged so as to overlap as shown in FIG. The discharge port 215 has a structure for discharging the sealing material 130 injected from the injection port 214 toward the application target (ends of the support base 110 and the reflective film 120). When the sealing material 130 is applied to the application target, the application target may be transported immediately below the discharge port 215 while discharging the sealing material 130 from the discharge port 215. Thereby, as shown in FIG. 6, the edge part of a coating target object is coat | covered with the sealing material 130. FIG.

The lower block 213 has a flat bottom surface and keeps the nozzle 153 parallel.

(B) Discharge port 215
Next, the detailed structure of the discharge port 215 will be described with reference to FIGS.

FIG. 7 is a schematic cross-sectional view of the nozzle of FIG. 6 taken along line 7A-7A. FIG. 8 is a schematic cross-sectional view of the nozzle taken along line 8A-8A in FIG. 6, and FIG. 9 is an enlarged view of FIG. FIG. 10 is an enlarged view of FIG. FIG. 11 is a schematic cross-sectional view of the nozzle taken along line 11A-11A in FIGS. 6 and 7, and FIG. 12 is an enlarged view of FIG.

As shown in FIG. 7, the nozzle 153 includes a first front lip 211a and a first back lip 211b for applying the sealing material 130 to the side surfaces of the support substrate 110 and the reflective film 120 (both components are collectively referred to as the first Called a nozzle). The first front lip 211 a and the first back lip 211 b are formed at the tip of the plate 211. When the direction in which the first front lip 211a and the first back lip 211b protrude is defined as the forward direction (hereinafter the same), the front end of the first back lip 211b is connected to the front end of the first front lip 211a. It is retreating against it. With this structure, the gap between the first back lip 211 b and the reflective film 120 becomes the discharge port 215 of the sealing material 130, so that the sealing material 130 can be applied to the side surfaces of the support base 110 and the reflective film 120.

Further, as shown in FIG. 8, the nozzle 153 includes a second front lip 212a and a second back lip 212b for applying the sealing material 130 to the surface (however, the end portion) of the reflective film 120. The second nozzle). The second front lip 212 a and the second back lip 212 b are formed at the tip of the middle block 212. Further, when the direction in which the second front lip 212a and the second back lip 212b protrude is defined as the forward direction (hereinafter the same), the tip of the second back lip 212b is connected to the tip of the second front lip 212a. It is retreating against it. With this structure, the gap between the second back lip 212b and the reflective film 120 becomes the discharge port 215 of the sealing material 130, and the sealing material 130 can be applied to the surface of the reflective film 120.

As described above, the first nozzle for the side surface and the second nozzle for the surface are integrally configured to form the discharge port 215 of the sealing material 130, the side surfaces of the support base 110 and the reflective film 120, and the reflection The sealing material 130 can be simultaneously applied to the surface of the film 120.

The space surrounded by the first front lip 211a, the first back lip 211b, the second front lip 212a, the second back lip 212b, and the lower block 213 is filled with the sealing material 130 from the inlet 214 to the outlet 215. It is used as a sealing material channel 216 to be flown.

Next, the sealing material channel 216 will be described with reference to FIGS. 9 and 10. The sealing material channel 216 includes an interval M1 between the first front lip 211a and the first back lip 211b, an interval M2 between the second front lip 212a and the second back lip 212b, and a second front lip 212a and a second back lip. The gap M3 (not shown) between the surface connecting the lip 212b and the lower block 213 is made constant, and a linear structure toward the discharge port 215 is provided. Therefore, the flow rate, the flow rate, and the like of the sealing material 130 flowing through the sealing material channel 216 are stable. As a result, the film thickness T2 is 0 mm <T2 ≦ 0.5 mm, and the coating width W is 0.5 mm ≦ W ≦ 2.0 mm. The thin film has a narrow width and high accuracy (the film thickness T2 and the coating width W are equal). Application is possible. Further, the widths (intervals M1, M2, M3) of the sealing material channel 216 are not limited to this, and may be appropriately adjusted according to the viscosity and flow rate of the sealing material 130.

Further, as shown in FIG. 9, the length L1 of the first back lip 211b in the conveying direction of the support substrate 110 and the reflective film 120 is such that the front end of the first back lip 211b is relative to the front end of the first front lip 211a. It is larger than the distance L2 that is retreating (L1> L2). With this shape, the sealing material 130 can be spread on the side surfaces of the support substrate 110 and the reflective film 120.

Similarly, as shown in FIG. 10, the length L3 of the second back lip 212b in the conveying direction of the support substrate 110 and the reflective film 120 is such that the tip of the second back lip 212b is at the tip of the second front lip 212a. On the other hand, it is larger than the distance L4 which is moving backward (L3> L4). With this shape, the sealing material 130 can be spread on the surface of the reflective film 120.

Further, the distance L2 at which the tip of the first back lip 211b is retreated with respect to the tip of the first front lip 211a is 1.5 times or more and 2.5 times or less the film thickness T1 of the sealing material 130. From the verification experiment, it is known that if the distance L2 is determined as described above, the coating can be performed with the expected film thickness T1.

Similarly, the distance L4 at which the tip of the second back lip 212b is retracted with respect to the tip of the second front lip 212a is not less than 1.5 times and not more than 2.5 times the film thickness T2 of the sealing material 130. . From the verification experiment, it is known that if the distance L4 is determined as described above, the coating can be performed with the expected film thickness T2.

Further, as shown in FIG. 9, the upstream end U1 of the first front lip 211a has a chamfered corner. Specifically, the corner portion of the upstream end U1 is chamfered in a curved shape so as to be curved with a predetermined radius of curvature. Or you may chamfer so that the corner | angular part of the upstream end U1 may become an obtuse angle of 120 degree | times or more. By the chamfered shape, the contact between the first front lip 211a and the transported supporting substrate 110 and the reflecting film 120 is made smooth (less friction), and the side surfaces of the supporting substrate 110 and the reflecting film 120 are damaged. I can prevent it. At the same time, the downstream end D1 of the first front lip 211a defines the sealing material channel 216, and the corner is formed at an angle of less than 120 degrees (preferably 90 degrees or less). The downstream end D1 of the first front lip 211a is preferably brought into contact with or slightly separated from the support substrate 110 and the reflective film 120 that have been transported. It is desirable to provide a moving mechanism (for example, a shock absorber, a spring, or the like) that moves the nozzle in accordance with a change in the position of the end portion.

Further, as shown in FIG. 9, the upstream end U2 of the first back lip 211b defines the sealing material flow path 216, and the corners are chamfered. Specifically, the corner portion of the upstream end U2 is chamfered in a curved shape so as to be curved with a predetermined radius of curvature. Or you may chamfer so that the corner | angular part of the upstream end U2 may become an obtuse angle of 135 degree | times or more. Due to the chamfered shape, the sealing material 130 that has come out of the sealing material flow path 216 can flow smoothly and smoothly to the side surfaces of the support base 110 and the reflective film 120. At the same time, the downstream end D2 of the first back lip 211b has a corner portion formed at an angle of 150 degrees or less (preferably 90 degrees or less), preferably a sharp edge. Thereby, it can prevent that the sealing material 130 goes around to the downstream side of the downstream end D2 of the 1st back lip 211b, and becomes a liquid separation defect.

Further, as shown in FIG. 10, the corner portion of the upstream end U3 of the second front lip 212a is chamfered. Specifically, the corner portion of the upstream end U3 is chamfered in a curved shape so as to be curved with a predetermined radius of curvature. Or you may chamfer so that the corner | angular part of the upstream end U3 may become an obtuse angle of 120 degree | times or more. The chamfered shape makes the contact between the second front lip 212a and the transported reflective film 120 smooth (less friction), and prevents damage to the upper surface of the reflective film 120. At the same time, the downstream end D3 of the second front lip 212a defines the sealing material flow path 216, and the corner is formed at an angle of less than 120 degrees (preferably 90 degrees or less). Therefore, the downstream end D3 of the second front lip 212a sandwiches the support base 110 and the reflection film 120 with the base 217, and flutters and vibrates in the vertical direction (gravity direction) of the support base 110 and the reflection film 120. Can be reduced.

Also, as shown in FIG. 10, the upstream end U4 of the second back lip 212b defines the sealing material flow path 216, and the corners are chamfered. Specifically, the corner portion of the upstream end U4 is chamfered in a curved shape so as to be curved with a predetermined radius of curvature. Or you may chamfer so that the corner | angular part of the upstream end U4 may become an obtuse angle of 135 degree | times or more. Due to the chamfered shape, the sealing material 130 that has come out of the sealing material channel 216 can flow smoothly and smoothly onto the upper surface of the reflective film 120. At the same time, the downstream end D4 of the second back lip 212b has a corner portion formed at an angle of 150 degrees or less (preferably 90 degrees or less), preferably a sharp edge. Thereby, it can prevent that the sealing material 130 goes around to the downstream side of the downstream end D4 of the 2nd back lip 212b, and becomes a liquid separation defect.

Further, as shown in FIGS. 11 and 12, when the second back lip 212b is observed along the line 11A-11A in FIGS. 6 and 7, the portion that contacts the surface of the reflective film 120 is cut out in a bowl shape. Such a recess 218 is provided. The width K of the recess 218 is substantially equal to the application width W of the sealing material 130 so that the application width W of the sealing material 130 is stabilized.

Also, the second back lip 212b is provided with the weir S at the end that contacts the surface of the reflective film 120, thereby preventing the sealing material 130 from leaking outside the recess 218. However, the distance L4 may be released toward the S end side in FIG. Even in that case, the coating width W of the sealing material 130 can be easily changed by adjusting the flow rate of the coating liquid. Moreover, the film thickness T2 of the sealing material 130 can be easily changed by changing the depth L4 of the recess 218 and the flow rate of the coating liquid.

Moreover, the film thickness T1 of the sealing material 130 can be easily changed by changing the distance L2 between the first back lip 211b and the reflective film 120 and the flow rate of the coating liquid.

Further, the space on the reflective film 120 (that is, the recess 218) and the space on the side surface of the support substrate 110 and the reflective film 120 (that is, the gap portion 219) are connected. Therefore, an L-shaped sealing material 130 as shown in FIG. 2 can be applied.

Further, the corner portion R of the concave portion 218 may be chamfered into a concave shape with a predetermined radius of curvature (for example, 1.5 mm). Since the chamfering process is performed, a connecting portion between the space on the surface of the reflective film 120 (that is, the concave portion 218) and the space on the side surface of the support substrate 110 and the reflective film 120 (that is, the gap portion 219) can be enlarged. As a result, the amount of the sealing material 130 necessary for forming the connection portion is increased, and the sealing material 130 is difficult to be peeled off at the connection portion.

In addition, in the nozzle 153, at least a part of the portion in contact with the sealing material 130 is covered with a material composed of a fluorine-based resin or a material containing a fluorine-based material (Teflon (registered trademark) or the like). . As a result, the flow of the sealing material 130 can be made smooth and cleaning can be facilitated, so that nozzle clogging due to the remaining sealing material 130 can be prevented. As a result, the life of the nozzle 153 can be extended. In addition, the nozzle 153 may be covered with a fluorine resin at least a part of the portion in contact with the support substrate 110 and the reflective film 120. Thereby, sliding with the nozzle 153, the support base material 110, and the reflective film 120 improves, and it becomes possible to apply at high speed. In particular, if a material containing a fluororesin is used, the hardness can be increased and the occurrence of shaving can be prevented.

<Operation of coating apparatus 150>
Next, a characteristic operation of the coating apparatus 150 according to the present embodiment will be described.

[Coating process]
FIG. 13 is a flowchart showing the procedure of the coating process executed in the coating apparatus.

After the power supply of the coating apparatus 150 is turned on, the reference position and the reference height of the structure to be coated with the sealing material 130 are set prior to the start of the coating process. For example, a reference structure is installed at an appropriate position by a user so that the structure is transported according to a predetermined transport guide provided in the transport mechanism, and the detection position of the first measuring device 157a at that time and the first position 2 The detection height of the measuring device 157b is registered in the control device 162 as a reference position. At this time, the first measuring device 157a and the second measuring device 157b are fixedly arranged (they do not move even if the first nozzle or the second nozzle moves), but can measure the shape of the end of the structure. As such, it may be finely adjusted.

In addition, after the power is turned on, the coating device 150 moves the first nozzle so that the width of the gap between the first back lip 211b and the side surface of the reflective film 120 is optimized, and serves as a reference position for the control device 162. And the second nozzle is moved so that the width of the gap between the second back lip 212b and the surface of the reflective film 120 is optimized, and is registered in the control device 162 as a reference height. Specifically, the tip of the first nozzle (first back lip 211b) is moved to a position away from the side surface of the structure registered as the reference position by an amount corresponding to the film thickness T1, and the position is changed to the first position. Register as the reference position of the nozzle. Similarly, the tip of the second nozzle (second back lip 212b) is moved to a position away from the surface of the structure registered as the reference position by an amount corresponding to the film thickness T2, and that position is moved to the second nozzle. Register as the reference height.

Thereafter, when an instruction to start application of the sealing material 130 is received from the user, the application device 150 starts the application process shown in FIG.

(Step S101)
When the coating process is started, the controller 162 moves the first nozzle and the second nozzle to a predetermined position within a movable range that is set in advance as a retreat position, and stops the movement.

For example, the control device 162 outputs an instruction to drive the first motor 156a to the first motor controller 165a so that the tip of the first nozzle (first back lip 211b) moves from the reference position to the retracted position. . The first motor 156a moves the nozzle 153 in a direction (arrow A shown in FIG. 5) perpendicular to the conveyance direction of the structure in accordance with an instruction from the first motor controller 165a.

At the same time, the control device 162 outputs an instruction for driving the second motor 156b to the second motor controller 165b so that the tip of the second nozzle (second back lip 212b) moves from the reference position to the retracted position. To do. The second motor 156b moves the nozzle 153 in the vertical direction (arrow B shown in FIG. 5) in accordance with an instruction from the second motor controller 165b.

(Step S102)
The transport mechanism of the coating apparatus 150 starts transporting the structure in which the reflective film 120 is bonded to the support base 110. Specifically, for example, the structure is transported by moving a transport table on which the structure is placed or fixed. Note that the transport mechanism of the coating apparatus 150 continues to transport the structure at a constant speed until the transport of the structure is stopped in step S110 described below.

(Step S103)
The detection device 161 controls at least the first measurement device 157a to detect the leading edge (hereinafter referred to as “starting edge”) of the structure in which the reflective film 120 is bonded to the support base 110 in the transport direction. . For example, when the first measurement device 157a is an imaging device such as a camera, the detection device 161 performs a general edge detection process on the image captured by the first measurement device 157a, and the first measurement device 157a. The starting edge of the structure conveyed to the position of is detected.

If the detection device 161 cannot detect the start point edge (step S103: NO), the detection device 161 repeats the process of step S103 until the start point edge is detected. On the other hand, when detecting the start point edge (step S103: YES), the detection device 161 supplies a signal indicating that the start point edge has been detected to the control device 162, and the process proceeds to step S104.

(Step S104)
The control device 162 moves the first nozzle and the second nozzle to a preset standby position. In order to shorten the time until the standby position moves to the control position and starts control in step S106, the front end of the first nozzle (first back lip 211b) and the front end of the second nozzle (second back lip 212b). ) Is preferably set at a position slightly away from the structure than the control position.

(Step S105)
The control device 162 determines whether or not a predetermined shift time has elapsed after the detection device 161 detects the start point edge. For example, the control device 162 starts measuring the elapsed time using a predetermined timer, and when the measured elapsed time exceeds a threshold registered in advance as the shift time, the predetermined shift time has elapsed. It is determined that As the shift time, a required time (estimated value) from when the start edge of the structure is detected to when the start edge reaches the position of the first nozzle may be registered. That is, a value (X1 / V) obtained by dividing the distance X1 in the conveyance direction between the first measuring device 157a and the first nozzle (specifically, the first front lip 211a) by the conveyance speed V is used as the shift time. Just register.

(Step S106)
The control device 162 detects the side surface of the structure detected by the detection device 161 so that the gap between the side surface (film end) of the structure and the tip of the first nozzle (first back lip 211b) is kept constant. Control (correction control) for moving the tip of the first nozzle is started in accordance with the position.

For example, when the first measurement device 157a is an imaging device such as a camera, the detection device 161 notifies the first measurement device 157a of a predetermined instruction so that the periphery of the end of the structure is imaged. Get the image. The detection device 161 detects the position of the side surface (film end) of the structure from the acquired image by image processing, and transmits the amount of deviation from the reference position to the control device 162. However, the reference position is a position registered before step S101 after power-on.

Then, the control device 162 gives an instruction to drive the first motor 156a so that the tip of the first nozzle moves by the amount of deviation from the reference position transmitted from the detection device 161. Output to. The first motor 156a moves the nozzle 153 in a direction (arrow A shown in FIG. 5) perpendicular to the conveyance direction of the structure in accordance with an instruction from the first motor controller 165a.

At the same time, the control device 162 adjusts the second according to the height of the surface of the structure detected by the detection device 161 so that the gap between the surface of the structure and the tip of the second nozzle is kept constant. Control (correction control) for moving the tip of the nozzle is started.

For example, when the second measurement device 157b is a laser displacement meter, the detection device 161 notifies the second measurement device 157b of a predetermined instruction, thereby irradiating the surface of the structure with laser light. The time until the reflected laser beam is received is measured. The detection device 161 acquires the measurement result (time signal or distance signal), detects the height of the surface of the structure, and transmits the amount of deviation from the reference height to the control device 162. However, the reference height is a height registered before step S101 after power-on.

Then, the control device 162 instructs the second motor controller 156b to drive the second motor 156b so that the tip of the second nozzle moves by the amount of deviation from the reference height transmitted from the detection device 161. To 165b. The second motor 156b moves the nozzle 153 in the vertical direction (arrow B shown in FIG. 5) in accordance with an instruction from the second motor controller 165b.

Note that the correction control described above continues to be performed until it ends in step S109 described later. In addition, while the correction control is being performed, the application control device 163 controls the discharge valve 152 to continuously apply the sealing material 130 to the side surface and the surface of the structure.

(Step S107)
The detection device 161 controls at least the first measurement device 157a to detect the last edge (hereinafter referred to as “end point edge”) in the transport direction of the structure in which the reflective film 120 is bonded to the support base 110. To do. For example, when the first measurement device 157a is an imaging device such as a camera, the detection device 161 performs a general edge detection process on the image captured by the first measurement device 157a, and the structure being conveyed. The end edge of is detected.

If the end device edge cannot be detected (step S107: NO), the detection device 161 repeats the process of step S107 until the end point edge is detected. On the other hand, when detecting the end point edge (step S107: YES), the detection device 161 supplies a signal indicating that the end point edge has been detected to the control device 162, and the process proceeds to step S108.

(Step S108)
The control device 162 determines whether or not a predetermined shift time has elapsed since the end point edge was detected by the detection device 161. For example, the control device 162 starts measuring the elapsed time using a predetermined timer, and when the measured elapsed time exceeds a threshold registered in advance as the shift time, the predetermined shift time has elapsed. It is determined that Note that the shift time used in step S108 is the same as the shift time used in step S105.

(Step S109)
The control device 162 ends the correction control started in step S106. At the same time, the application control device 163 controls the discharge valve 152 to finish the application of the sealing material 130 to the side surface and the surface of the structure.

(Step S110)
The conveyance mechanism of the coating apparatus 150 stops the conveyance of the structure started in step S102. For example, the conveyance of the structure is stopped by stopping the movement of the conveyance table on which the structure is placed or fixed.

Thereafter, the coating apparatus 150 ends the coating process after moving the first nozzle and the second nozzle to the retreat position.

By performing the above coating process in the coating apparatus 150, the tips of the first nozzle and the second nozzle are moved according to the curvature (swell, unevenness, distortion, etc.) of the ends of the support base 110 and the reflective film 120. The sealing material 130 can be applied while being moved. Thereby, even when the support base 110 and the end of the reflective film 120 are curved, it is possible to apply the sealing material 130 with a uniform film thickness. As a result, reduction of the sealing effect can be prevented. Further, it is possible to apply a thinner sealing material, and it can be expected to save the sealing material and improve productivity by shortening the curing time of the sealing material.

In addition, the first and second motors 156a and 156b are used in which the position accuracy of the tips of the first and second nozzles is 1/3 or less of the coating thickness (T1, T2) of the sealing material 130. Application of the sealing material 130 with sufficiently high film thickness uniformity is possible.

<Example>
EXAMPLES Hereinafter, the present invention will be specifically described with reference to examples, but the present invention is not limited thereto. In addition, although the display of "%" is used in an Example, unless otherwise indicated, "mass%" is represented.

(1) Example 1
[Production of Solar Reflecting Panel of Example 1-1]
(A) Production of reflective film 120 (A-1) Resin support layer 127
A biaxially stretched polyester film (polyethylene terephthalate film, thickness 100 μm) was used as the resin substrate (resin support layer 127).

(A-2) Anchor layer 126
On one side of the polyethylene terephthalate film, (1) polyester resin (Polyester SP-181, Nippon Synthetic Chemical Co., Ltd.), (2) melamine resin (Super Becamine J-820, manufactured by DIC), (3) TDI isocyanate (2 , 4-tolylene diisocyanate), (4) HDI isocyanate (1,6-hexamethylene diisocyanate) at a resin solid content ratio of 20: 1: 1: 2 (mass ratio) so that the solid content concentration becomes 10%. Then, a resin liquid mixed in toluene was coated by a gravure coating method to form an anchor layer 126 having a thickness of 0.1 μm.

(A-3) Reflective layer 121
Next, a silver reflective layer having a thickness of 80 nm was formed as a reflective layer 121 on the anchor layer 126 by a vacuum deposition method.

(A-4) Corrosion prevention layer 122
Further, a polyester resin and a TDI (tolylene diisocyanate) isocyanate resin are mixed at a resin solid content ratio of 10: 2 on the silver reflective layer (reflective layer 121), and coated by a gravure coating method. A 1 μm corrosion prevention layer 122 was formed.

(A-5) Hard coat layer 125
Next, on the corrosion prevention layer 122, a 3% perhydropolysilazane solution in dibutyl ether (NL120 manufactured by AZ Electric Materials Co., Ltd.) was bar-coated so that the film thickness after drying was 500 nm, and 3 minutes After natural drying, the hard coat layer 125 was formed by annealing in an oven at 90 ° C. for 30 minutes.

(A-6) Antifouling Layer Further, a water repellent (Aquanolan manufactured by AZ Electric Material Co., Ltd.) was bar coated on the hard cord layer 125 to form an antifouling layer.

The reflective film 120 was produced by the above procedures (A-1) to (A-6).

(B) Bonding of reflective film 120 The reflective film 120 produced as described above was cut into a length of 1000 mm and a width of 1000 mm. The back surface of the resin support layer 127 (the surface opposite to the light incident side) is placed on an aluminum plate (support base material) having a thickness of 0.5 mm and a length of 1000 mm × width of 1000 mm through an adhesive layer 128 having a thickness of 3 μm. 110). That is, the reflective film 120 is bonded according to the shape of the support substrate 110 so that the support substrate 110 and the side surfaces (end portions) are aligned.

(C) Application of Sealant 130 Thereafter, the side surfaces of the support substrate 110 and the reflective film 120 are covered, and the surfaces of the reflective film 120 are covered from the side surfaces as shown in FIGS. The sealing material 130 was applied using an extrusion type coating apparatus 150.

In addition, the corner | angular part of the upstream end U1 of the 1st front lip 211a was formed in the curve shape whose curvature radius is 2 mm. The corner of the downstream end D1 of the first front lip 211a was formed as a right sharp edge. The corner portion of the upstream end U2 of the first back lip 211b was formed in a curved shape with a curvature radius of 1 mm. The corner of the downstream end D2 of the first back lip 211b was formed as a right sharp edge. The length L1 of the first back lip 211b was 3 mm. The width (the width of the recess 218) K of the first back lip 211b was 1.5 mm. The distance L2 at which the tip of the first back lip 211b is retracted with respect to the tip of the first front lip 211a was 0.8 mm. The interval M1 between the first front lip 211a and the first back lip 211b was 3 mm.

The corner of the upstream end U3 of the second front lip 212a was formed in a curved shape with a radius of curvature of 2 mm. The corner of the downstream end D3 of the second front lip 212a was formed as a right-angled sharp edge. The corner of the upstream end U4 of the second back lip 212b was formed in a curved shape with a curvature radius of 1 mm. The corner of the downstream end D4 of the second back lip 212b was formed as a right sharp edge. The length L3 of the second back lip 212b was 3 mm. The distance L4 at which the tip of the second back lip 212b is retracted with respect to the tip of the second front lip 212a was 0.8 mm. The distance M2 between the second front lip 212a and the second back lip 212b was 3 mm.

Further, the second back lip 212b is provided with a weir S at an end portion that contacts the upper surface of the reflective film 120. The corner portion R of the recess 218 provided in the second back lip 212b is chamfered so as to be bent with a curvature radius of 1.5 mm.

The first front lip 211a, the first back lip 211b, the second front lip 212a, and the second back lip 212b (hereinafter may be collectively referred to as “lip”) include Teflon (registered trademark). Resin was used.

Further, as the sealing material 130, a silicon sealant (KE-45G manufactured by Shin-Etsu Silicone Co., Ltd.) was used.

Moreover, the conveyance speed which conveys the apply | coating object (the support base material 110 and the reflective film 120) was 10 m / min.

An image processing camera XG-035 (first measuring device 157a) manufactured by Keyence Corporation was used for detecting the position of the side surface (film end) of the structure. From the image taken with the camera, the position of the side surface of the structure was detected by image processing using KV-5000 (detection device 161) manufactured by Keyence Corporation. The amount of deviation from the reference position is transferred to the motor control PLC (control device 162), and the first motor 156a is moved in the direction perpendicular to the side surface of the structure by the amount of deviation to move the first nozzle. Control was performed so that the distance between the side of the object and the tip of the first nozzle was always the same. The distance between the camera and the first nozzle in the application (conveyance) direction was 100 mm. Since the transport speed V is 10 m / min, 0.6 seconds after the camera detects the starting edge of the structure, the starting edge reaches the position facing the first nozzle, and from that point on the side of the structure A sealing material 130 is applied to the film. Therefore, the time delay is set to 0.6 seconds, and the first nozzle is moved to a control position where the sealing material 130 can be applied with the specified film thickness T1 after 0.6 seconds of camera detection.

Further, a CCD laser displacement meter LK035 (second measuring device 157b) manufactured by Keyence Corporation was used for detecting the position of the surface of the structure. The displacement meter was installed at a position 100 mm ahead of the second nozzle so as to face the upper surface of the end of the structure, and the height of the surface of the structure was analyzed (detection device 161) and detected. The amount of deviation from the reference position is transferred to the motor control PLC (control device 162) and the second motor 156b is operated in the direction perpendicular to the surface of the structure (up and down direction) by the amount of deviation. It was moved and controlled so that the distance between the surface of the structure and the tip of the second nozzle was always the same. Since the conveyance speed V is 10 m / min, the start edge reaches a position facing the second nozzle 0.6 seconds after the camera detects the start edge of the structure, and the surface of the structure from that point onward. A sealing material 130 is applied to the film. Therefore, the time delay is set to 0.6 seconds, and the second nozzle is moved to a control position where the sealing material 130 can be applied with the specified film thickness T2 after 0.6 seconds of camera detection.

Application of the sealing material 130 as described above is continuously performed along the outer edge of the end of the structure, the application length L is 1 m, the application width W is 1.5 mm, and the film thicknesses T1 and T2 are 0.00. A solar reflective panel of Example 1-1 having a thickness of 4 mm was produced.

[Production of Solar Reflecting Panels of Examples 1-2 to 1-5]
The solar reflective panels of Examples 1-2 to 1-5 were produced by the same method as that of Example 1-1 except for the following points.

Example 1-2: Conveying speed V 10 m / min, coating length L 2 m
Example 1-3: Conveying speed V 10 m / min, coating length L 4 m
Example 1-4: Conveying speed V 5 m / min, coating length L 1 m
Example 1-5: Conveying speed V 2.5 m / min, coating length L 1 m
However, V is a conveyance speed of a structure, and L is a length (equal to the length of the support base material 110) which applies the sealing material 130 continuously.

(2) Example 2
[Production of Solar Reflecting Panel of Example 2]
Using Keyence's ultra-high-speed inline profile measuring instrument LJ-V (in combination with the first and second measuring devices 157a and 157b), detecting the position of the side surface (film edge) of the structure and the height of the surface of the structure Detection was performed at the same time. The amount of deviation from each reference position and reference height is transferred to the motor control PLC (control device 162), and the first motor 156a is moved in the direction perpendicular to the side of the structure to move the first nozzle. The distance between the side surface of the structure and the tip of the first nozzle was always controlled to be the same. Also, the second motor 156b is operated in a direction (vertical direction) perpendicular to the surface of the structure to move the second nozzle so that the distance between the surface of the structure and the tip of the second nozzle is always the same. Controlled.

The distance in the coating (conveying) direction between the measuring instrument (first measuring device 157a) and the first and second nozzles was 100 mm. Since the conveyance speed V is 10 m / min, 0.6 seconds after the measuring device detects the starting point edge of the structure, the starting point edge reaches the position facing the first and second nozzles, and the structure is started from that point. A sealing material 130 is applied to the surface of the object. Therefore, the time delay is set to 0.6 seconds, and the first and second nozzles are moved to a control position where the sealing material 130 can be applied with the specified film thicknesses T1 and T2 0.6 seconds after the detection of the measuring instrument. did.

Application of the sealing material 130 as described above is continuously performed along the outer edge of the end of the structure, the application length L is 1 m, the application width W is 1.5 mm, and the film thicknesses T1 and T2 are 0.00. A solar reflective panel having a thickness of 4 mm was produced.

Other points were produced in the same manner as in Example 1-1.

(3) Example 3
[Production of Solar Reflecting Panel of Example 3]
FIG. 14 is a diagram showing the shape of the sealing material of the solar reflective panel produced in Example 3. FIG. 15 is a diagram illustrating a tip portion (ejection port) of a nozzle used when the solar reflective panel of Example 3 is manufactured.

In the solar reflective panel of Example 3, the reflective film 120 having a smaller size than the support base 110 is bonded to the support base 110 (aluminum base). The end portions of the support base 110 and the reflection film 120 are not aligned as shown in FIG. 14, and the sealing material 130 is applied so as to cover the end portions of the reflection film 120.

As in Example 2, using the ultra-high-speed inline profile measuring device LJ-V (using both the first and second measuring devices 157a and 157b), the position detection of the end of the reflective film 120 and the surface of the reflective film 120 are performed. The height detection was performed simultaneously.

Further, the sealing material 130 was applied using a frame type nozzle (see Japanese Patent Application No. 2014-091737) as shown in FIG. 15 as the nozzle 153 (discharge port 215).

Application of the sealing material 130 as described above is continuously performed along the end of the reflective film 120, the application length L is 1 m, the application width W is 1.0 mm, the film thickness T1 is 1.5 mm, and the film A solar reflective panel having a thickness T2 of 0.5 mm was produced.

Other points were produced in the same manner as in Example 1-1.

(4) Comparative Example 1
[Production of Solar Reflecting Panel of Comparative Example 1]
The first and second nozzles were fixed without using the motor control by the first motor 156a and the second motor 156b, and the same method as in Example 1-1 was used.

[Production of Solar Reflecting Panels of Comparative Examples 1-2 to 1-5]
The solar reflective panels of Comparative Examples 1-2 to 1-5 were produced by the same method as Comparative Example 1-1 except for the following points.

Comparative Example 1-2: Conveying speed V 10 m / min, coating length L 2 m
Comparative Example 1-3: Conveying speed V 10 m / min, coating length L 4 m
Comparative Example 1-4: Conveying speed V 5 m / min, coating length L 1 m
Comparative Example 1-5: Conveying speed V 2.5 m / min, coating length L 1 m
However, V is a conveyance speed of a structure, and L is a length (equal to the length of the support base material 110) which applies the sealing material 130 continuously.

(5) Comparative Example 2
[Production of Solar Reflecting Panel of Comparative Example 2]
The first and second nozzles were fixed without using the motor control by the first motor 156a and the second motor 156b, and the same method as in Example 3 was used.

<Evaluation of solar reflective panel>
The following evaluation was performed about each solar reflective panel produced as mentioned above.

[Evaluation of coating quality 1]
About each solar reflective panel produced as mentioned above, the cross-sectional shape of the sealing material 130 was measured using the commercially available laser displacement sensor. Specifically, the coating width W on the surface of the reflective film 120, the film thickness T1 on the side surface of the reflective film 120, the film thickness T2 on the surface of the reflective film 120, and a plurality of points over the entire length applied (20 points at a 50 mm pitch). Measured with And from each of measured W, T1, and T2, the difference of the maximum value and the minimum value was computed, and the coating quality was evaluated.

[Evaluation of coating quality 2]
Furthermore, it visually observed from the side surface direction of each solar reflective panel, and coating quality was evaluated according to the following reference | standard.

5: Almost all sides of the solar reflective panel are covered with the sealing material 130, which is of good quality. 4: A portion of the side of the solar reflective panel not covered with the sealing material 130 is slightly recognized. However, the reflective layer 121 is sufficiently covered and has no problem. 3: The side of the solar reflective panel is slightly covered with the sealing material 130, but the reflective layer 121 is covered. 2: The quality that is practically acceptable 2: The side surface of the solar reflective panel is often not covered with the sealing material 130, and the reflective layer 121 is exposed, which is a practical problem. 1: There is a portion that is not covered at all by the sealing material 130 on the side surface of the solar reflective panel, and the reflective layer 121 is completely exposed, and the quality is not practical. <Evaluation Result>
Next, the results obtained by the above evaluation experiment will be described.

FIG. 16 is a diagram showing the evaluation results of coating quality 1 and 2.

As shown in FIG. 16, if application is performed while moving the first and second nozzles using motor control by the first and second motors 156a and 156b, the application width W and the film thickness T1 of the sealing material 130 are applied. , T2 was found to be uniformly applied (Example 1). This result is the same even when measuring both the shape of the side surface and the surface of the structure using only one measuring device as in Example 2 or when applying using a frame type nozzle as in Example 3. (Examples 2 and 3). In addition, when the difference between the maximum value and the minimum value of W, T1, and T2 of the coating quality 1 shown in FIG. 16 was less than 0.1 mm, it was determined to be uniform (hereinafter the same).

Further, if the application is performed while moving the first and second nozzles using the motor control by the first and second motors 156a and 156b, the application quality is excellent (the above evaluation criteria is 4 or 5). It was also found that a light reflecting panel was obtained (Examples 1 to 3).

On the other hand, if application is performed with the first and second nozzles fixed without using motor control by the first and second motors 156a and 156b, the coating width W and the film thicknesses T1 and T2 of the sealing material 130 are applied. As a result, it was found that only solar reflective panels with poor coating quality 2 could be obtained (Comparative Examples 1 and 2).

Moreover, even if the length of the sealing material 130 applied to the end portion of the structure is 1 m or more, the application width W and the film thicknesses T1 and T2 of the sealing material 130 are uniform without any problem. It was also found that it was applied (Examples 1 to 3).

<Modification>
The above embodiments are intended to exemplify the gist of the present invention and do not limit the present invention. Many alternatives, modifications, and variations will be apparent to those skilled in the art. Examples of modifications include the following.

For example, in the above-described embodiment, an example in which the L-shaped sealing material 130 is applied to the side surfaces of the support substrate 110 and the reflection film 120 and the surface of the reflection film 120 is described. Further, as shown in FIG. 14, an example in which a reflective film 120 having a size smaller than that of the support base 110 is bonded to the support base 110 and a sealing material 130 is applied so as to cover the end of the reflective film 120. Also explained. However, the present invention is not limited to these examples. As long as the sealing material 130 is applied to at least one surface of the support substrate 110 and the reflective film 120 and at least the side surface of the reflective film 120, the present invention is appropriately selected. You may change it.

FIG. 17 is a view showing a modification of the shape of the sealing material 130. For example, as shown in FIG. 17, a sealing material 130 is applied in a U shape to the surfaces on both sides of the support substrate 110 and the reflection film 120 and the side surfaces of the support substrate 110 and the reflection film 120. May be. Thereby, the support base material 110 and the reflective film 120 can be sealed more reliably.

Further, as long as at least the boundary between the support substrate 110 and the reflective film 120 can be covered with the sealing material 130, the sealing material 130 may be applied only to a part of the side surfaces of the support substrate 110 and the reflective film 120. Thereby, the volume of the sealing material 130 required for application | coating can be reduced and manufacturing cost can be held down.

Moreover, in the said embodiment, the example which manufactures the panel 100 for sunlight reflection which bonded the reflective film 120 to the support base material 110, and apply | coated the sealing material 130 to the edge part is given. However, the present invention is not limited to this. For example, a film support in which a film that is not the reflective film 120 is bonded to the support base 110 and the sealing material 130 is applied to the end thereof may be manufactured.

Moreover, in the said embodiment, a sealing material is used using the 1st nozzle comprised from the 1st front lip 211a and the 1st back lip 211b, and the 2nd nozzle comprised from the 2nd front lip 212a and the 2nd back lip 212b. An example in which 130 is applied will be described. However, the present invention is not limited to this, and any shape of nozzle may be used.

Note that this application is based on Japanese Patent Application No. 2015-014785 filed on January 28, 2015, the disclosures of which are referenced and incorporated as a whole.

100 solar reflective panel,
110 support substrate,
120 reflective film,
121 reflective layer,
122 anticorrosion layer,
123 UV absorbing layer,
124 gas barrier layer,
125 hard coat layer,
126 anchor layer,
127 resin support layer,
128 adhesive layer,
130 encapsulant,
150 coating device,
151 tanks,
152 discharge valve,
153 nozzles,
154 LM Guide,
155 movable stage,
156a first motor,
156b second motor,
157a first measuring device,
157b second measuring device,
161 detection device,
162 controller,
163 coating control device,
164 monitor,
165a first motor controller,
165b Second motor controller,
211a first front lip,
211b first back lip,
212a second front lip,
212b Second back lip,
215 discharge port,
216 encapsulant flow path,
W coating width,
T1, T2 Film thickness.

Claims (12)

It is an application method for applying a sealing material to the film end of a structure in which a film is bonded to a support substrate,
(A) prior to application of the sealing material, detecting the position of the film end and the height of at least one of the surfaces of the film end on the side of the support base and the film;
(B) The tip of the first nozzle according to the position of the film end detected in step (a) so that the gap between the film end and the tip of the first nozzle is kept constant. Applying the sealing material while moving
(C) according to the height of the surface detected in the step (a) so that the gap between the surface of the film end and the tip of the second nozzle is kept constant. Applying the sealing material while moving the tip;
A coating method comprising: The coating method according to claim 1, wherein in step (a), the position of the film edge and the height of the surface are detected using a displacement sensor or a camera. In the step (b), the tip of the first nozzle is moved by driving the first motor,
The coating method according to claim 1, wherein in step (c), the tip of the second nozzle is moved by driving a second motor. In the step (b), the structure is conveyed relative to the first nozzle, and after the start point of the structure is detected in the step (a), the start point is set at the position of the first nozzle. When it reaches, start the control to move the tip of the first nozzle,
In the step (c), the structure is transported relative to the second nozzle, and after the start point of the structure is detected in the step (a), the start point is set at the position of the second nozzle. The coating method according to any one of claims 1 to 3, wherein when it reaches, control for moving the tip of the second nozzle is started. In the step (b), the structure is conveyed relative to the first nozzle, and after the end point of the structure is detected in the step (a), the end point is set to the position of the first nozzle. When reaching, the control of moving the tip of the first nozzle is terminated,
In the step (c), the structure is conveyed relative to the second nozzle, and after the end point of the structure is detected in the step (a), the end point is set to the position of the second nozzle. The coating method according to any one of claims 1 to 4, wherein when it reaches, control for moving the tip of the second nozzle is started. The coating method according to any one of claims 1 to 5, wherein the positional accuracy of the tips of the first nozzle and the second nozzle is 1/3 or less of the coating thickness of the sealing material. The coating method according to any one of claims 1 to 6, wherein a length of the sealing material applied to the film end is 1 m or more. The coating method according to any one of claims 1 to 7, wherein a conveyance speed of the structure with respect to the first nozzle and the second nozzle is 5 m / min or more. The film is a reflective film for reflecting sunlight,
The coating method according to any one of claims 1 to 8, wherein the structure having the sealing material applied to an end portion thereof is a solar reflective panel. The integrally formed first nozzle and second nozzle are used for applying the sealing material in the step (b) and the step (c), according to any one of claims 1 to 9. The coating method as described. A coating apparatus that coats the sealing material by the coating method according to any one of claims 1 to 10. (A) bonding the film to the supporting substrate in accordance with the shape of the supporting substrate;
(B) applying a sealing material to the film end of the structure formed by bonding in the step (a), and
A panel manufacturing method in which, in the step (b), the sealing material is applied by the coating method according to any one of claims 1 to 10.

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