Method for manufacturing a solar panel

Abstract

Method for manufacturing a solar panel (50), wherein the method comprises the following steps: Preparing a laminated body (40) which a protective cover (41) made of plastic, which is translucent from a front surface (410) to a rear surface (411) and which is curved in a convex manner from the rear surface (411) towards the front surface (410), a flat plastic rear cover (43) arranged to face the rear surface (411) of the protective cover (41), a photovoltaic battery cell (451), and has an encapsulation (47) that holds the photovoltaic battery cell (451) in an encapsulated state between the protective cover (41) and the back cover (43); Mounting the laminated body (40) on a laminating clamping device (3) such that the back cover (43) rests against the laminating clamping device (3); and Heating the laminated body (40) with the laminating clamping device (3) until the temperature of the back cover (43) reaches or exceeds a glass transition temperature, and compression bonding the laminated body (40) by holding the laminated body (40) between a membrane (7) and the laminating clamping device (3), thereby obtaining a solar panel (50) from the laminated body (40), wherein the laminating clamping device (3) is curved in a convex manner towards the laminated body (40), the method is characterized by the fact that Mounting the laminated body (40) on the laminating clamping device (3) includes mounting the laminated body (40) on a support surface (310) of the laminating clamping device (3) which is curved in a convex manner, the protective cover (41) has one or more engagement projections (414, 415) extending from the rear surface (411) to the laminating clamping device (3), Each of the back cover (43) and the encapsulation (47) has one or more through holes (430a, 430b, 471a, 471b, 472a, 472b) through which one or more engagement projections (414, 415) are inserted accordingly, the laminating clamping device (3) has one or more engagement holes (31a, 31b), and Mounting the laminated body (40) on the laminating clamping device (3) includes positioning the laminated body (40) relative to the support surface (310) by appropriately inserting one or more engagement projections (414, 415) into one or more through holes (430a, 430b, 471a, 471b, 472a, 472b) and into one or more engagement holes (31a, 31b).

Description

BACKGROUND

[0001] The present disclosure relates to a method for manufacturing a solar panel.

[0002] JP 2010-149506 A discloses a conventional method for manufacturing a solar panel (hereinafter referred to simply as the conventional manufacturing method). The conventional manufacturing method includes a preparation step, an assembly step, and a lamination step. The conventional method involves the use of a lamination device comprising a membrane, a lamination jig, and a heating unit. The membrane faces the lamination jig. The heating unit can heat the lamination jig.

[0003] In the conventional manufacturing process, the preparation step is performed first. The preparation step involves preparing a laminated body including a protective cover, a back cover, photovoltaic battery cells, and an encapsulant. The protective cover is translucent from its front surface to its back surface and is curved in a convex manner from the back surface to the front surface. The back cover is a flat plate. The above-described document does not explicitly describe the materials of the protective cover and the back cover. The protective cover is generally made of glass, but may recently be made of plastic from the perspective of weight reduction. The back cover is generally made of plastic.

[0004] The photovoltaic battery cells are arranged in a matrix. The encapsulation comprises two encapsulation plates, namely a first encapsulation plate and a second encapsulation plate. The laminated body is formed by laminating the protective cover, the first encapsulation plate, the photovoltaic battery cells, the second encapsulation plate, and the back cover in this order.

[0005] Then, the assembly step is performed. In the assembly step, the laminated body is mounted on the laminating jig, with the protective cover, specifically the front cover of the protective cover, abutting the laminating jig. The laminating jig is curved so that its central portion is recessed in accordance with the shape of the protective cover. Thus, mounting the laminated body on the laminating jig causes the front surface of the protective cover to abut the laminating jig.

[0006] Next, the lamination step is performed. In the lamination step, the lamination jig heated by the heating device is pressed onto the protective cover to heat the laminated body. This softens the back cover and the two encapsulating plates. In this state, the laminated body is held between the membrane and the lamination jig to compression-bond the laminated body. This causes the back cover to be pressed through the membrane and curved in a convex manner toward the protective cover to form a product shape. Furthermore, the two softened encapsulating plates are integrated so that the encapsulation keeps the photovoltaic battery cells encapsulated between the protective cover and the back cover. This integrates the protective cover, the back cover, the photovoltaic battery cells, and the encapsulation.This is how the solar panel is manufactured. The front surface of the protective cover serves as a design surface.

[0007] In the conventional manufacturing method described above, curving the back cover from a flat shape into the product shape in a preferable manner requires that the back cover be heated to a glass transition temperature and sufficiently softened.

[0008] However, in the conventional manufacturing method, since the front surface of the protective cover abuts the lamination jig, the back cover is located at the furthest position from the lamination jig in the laminated body. Consequently, heating the back cover to the glass transition temperature would require the lamination jig to be heated to a correspondingly high temperature and pressed onto the protective cover. If the protective cover is made of plastic, heating the back cover to a high temperature by the lamination jig causes the protective cover to reach the glass transition temperature. This unnecessarily softens the protective cover and slightly roughens its front surface, thereby deteriorating the aesthetic appearance of the manufactured solar panel.

[0009] Heating the laminated body to prevent the plastic protective cover from reaching the glass transition temperature prevents the back cover from reaching the glass transition temperature and sufficiently softening. Thus, the protective cover is not curved in a preferred manner. This causes, for example, the back cover to wrinkle and air to become trapped between the back cover and the encapsulant. Consequently, the conventional manufacturing process makes it difficult to produce a high-quality solar panel that has a plastic protective cover and a plastic back cover.

[0010] EP 3 028 854 A1 discloses a method for producing a solar panel according to the preamble of claim 1. SUMMARY

[0011] It is an object of the present disclosure to provide a method for manufacturing a solar panel having a plastic protective cover and a plastic back cover of high quality.

[0012] The object of the invention is achieved by a method for producing a solar panel according to claim 1. Advantageous developments of the invention are the subject of the dependent claims.

[0013] Other features, aspects and advantages will become apparent from the following description, taken together with the accompanying drawings and the claims. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a cross-sectional view showing a solar panel manufactured by a manufacturing method according to a first embodiment. Fig. 2 is a cross-sectional view showing a laminating apparatus in the manufacturing method according to the first embodiment. Fig. 3 is a flowchart illustrating the manufacturing method according to the first embodiment. Fig. 4 is an enlarged cross-sectional view showing a laminated body and the like in the manufacturing method according to the first embodiment. Fig. Fig. 5 is a partial cross-sectional view showing a state in which a laminating jig of Fig. 2 a laminated body of Fig. 4 in the manufacturing method according to the first embodiment. Fig. Fig. 6 is an enlarged cross-sectional view showing a state in which a membrane and the laminating jig are used to laminate the body of Fig. 4 in a lamination step in the manufacturing method according to the first embodiment. Fig. 7 is a graph illustrating changes in temperature of a protective cover and a back cover in the manufacturing method according to the first embodiment. Fig. 8 is a partial cross-sectional view showing a state in which the laminating jig supports the laminated body in a manufacturing method according to a second embodiment. DETAILED DESCRIPTION

[0014] A first embodiment and a second embodiment of the present invention will now be described with reference to the drawings. First embodiment

[0015] As in Fig. As shown in Figure 1, a vehicle solar panel 50 includes a protective cover 41, a back cover 43, a photovoltaic string 45, and an encapsulant 47. The vehicle solar panel 50 is an example of a solar panel in the present invention. The vehicle solar panel 50 is used for a vehicle (not shown) and is attached to its roof panel. The protective cover 41, the back cover 43, the photovoltaic string 45, and the encapsulant 47 are described in detail below.

[0016] In the present embodiment, the direction referred to as “front” in Fig. 1 is the front side of the vehicle solar panel 50, and the direction referred to as “rear” in Fig. 1 corresponds to the rear side of the vehicle solar panel 50 to define the front-to-rear direction of the vehicle solar panel 50. Furthermore, the direction indicated as "top" in Fig. 1, the upper part of the vehicle solar panel 50, and the direction indicated as “down” in Fig. 1 corresponds to the lower part of the vehicle solar panel 50 to define the vertical direction, ie the thickness direction of the vehicle solar panel 50. In Fig. 2 to 8 are the directional axes forward, backward, up and down in accordance with Fig. 1. These directions are merely examples for explanation and are irrelevant for the directions during use of the vehicle solar panel 50.

[0017] Manufacturing the vehicle solar panel 50 involves using a laminating device 100, which in Fig. 2. The laminating apparatus 100 includes a housing, a laminating chuck 3, a heater 5, a membrane 7, a first tube 9, a second tube 11, a first pump 13, and a second pump 15.

[0018] The housing 1 includes a first housing 17 and a second housing 19. The first housing 17 has a flat bottom wall 17a and a first side wall 17b extending upward from the bottom wall 17a to the second housing 19. The second housing 19 is coupled to the first housing 17 so as to be openable and closable and is located on the upper side of the first housing 17. The second housing 19 has a flat top wall 19a and a second side wall 19b extending downward from the top wall 19a to the first housing 17.

[0019] Closing the second housing 19 relative to the first housing 17 causes the first side wall 17b to abut the second side wall 19b. This defines a vacuum chamber 21 within the housing 1. Although not shown in the drawings, the first side wall 17b and the second side wall 19b are provided with a seal that encapsulates a portion between the vacuum chamber 21 and the outside of the housing 1.

[0020] Furthermore, the first pipe 9 is attached to the bottom wall 17a, and the second pipe 11 is attached to the top wall 19a. Furthermore, the first pipe 9 is provided with the first pump 13, and the second pipe 11 is provided with the second pump 15. The first pump 13 and the second pump 15 can each discharge air from the vacuum chamber 21 through the first and second pipes 9 and 11 and supply air into the vacuum chamber 21.

[0021] The lamination chuck 3 is located in the first housing 17, i.e., in the vacuum chamber 21. The lamination chuck 3 is made of a metal such as aluminum and has a support surface 310, a bottom surface 311, and an outer peripheral surface 312.

[0022] The support surface 310 serves as the upper surface of the laminating jig 3. As shown in Fig. 4, the support surface 310 is curved in a convex manner toward the upper side of the vacuum chamber 21, that is, toward a laminated body 40 (which will be described later) with a curvature corresponding to the product shape (see Fig. 1) of the back cover 43. Thus, the laminating jig 3 allows the back cover 43 to have the product shape, ie, to be curved in a convex manner toward the protective cover 41. Furthermore, as shown in Fig. 4, the support surface 310, and thus the laminating jig 3, is larger than the protective cover 41 and the back cover 43. Moreover, the center and front sides of the support surface 310, that is, the center and front sides of the laminating jig 3, respectively have a first engagement hole 31a and a second engagement hole 31b recessed downward from the support surface 310. In other words, the first engagement hole 31a is located on the upper side of the support surface 310, which is the most protruding part of the support surface 310, and the second engagement hole 31b is located on the outer edge of the support surface 310. The opening of the second engagement hole 31b is larger than that of the first engagement hole 31a.

[0023] As in Fig. As shown in Figure 2, the bottom surface 311 is located on the side opposite the support surface 310 and has a flat shape. The outer peripheral surface 312 is continuous with the support surface 310 and the bottom surface 311 and extends along the outer edges of the support surface 310 and the bottom surface 311.

[0024] The heater 5 is provided in the vacuum chamber 21. Specifically, the heater 5 is located at the bottom of the laminating chuck 3 in the first housing 17. The heater 5 includes a heater housing 5a and a heater main body 5b. The heater housing 5a is made of a metal such as stainless steel. The heater housing 5a is larger than the laminating chuck 3 and has a rectangular shape. The laminating chuck 3 is mounted on the heater housing 5a. This causes the bottom surface 311 of the laminating chuck 3 to abut against the heater housing 5a. Furthermore, the heater housing 5a is fixed to the bottom wall 17a of the first housing 17 by legs 5c. The heater main body 5b is housed in the heater housing 5a. Ceramic heaters can be used, for example.for the heater main bodies 5b. Each of the heater main bodies 5b generates heat when supplied with power from a power supply device (not shown). Thus, the heater 5 can heat the laminating chuck 3. The number of heater main bodies 5b can be changed.

[0025] The diaphragm 7 is made of a heat-resistant synthetic rubber that can withstand the heat of the lamination jig 3 and is elastically deformable. The outer edge of the diaphragm 7 is fixed to the second side wall 19b of the second housing 19 so that the diaphragm 7 is attached to the inner side of the second housing 19. Thus, the diaphragm 7 is located above the lamination jig 3 in the vacuum chamber 21 and faces the lamination jig 3. Furthermore, the diaphragm 7 divides the vacuum chamber 21 into a first vacuum region 21a located on the lower side of the diaphragm 7 and a second vacuum region 21b located on the upper side of the diaphragm 7.

[0026] The vehicle solar panel 50, which is Fig. 1 is manufactured by the manufacturing method according to the first embodiment. As shown in Fig. 3, the manufacturing method includes a preparation step S1, an assembly step S2 and a lamination step S3.

[0027] In the manufacturing process, the preparation step S1 is carried out first. In the preparation step S1, as shown in Fig. 4, the laminated body 40 is prepared, which has the protective cover 41, the back cover 43, the photovoltaic chain 45 and the encapsulation 47.

[0028] The protective cover 41 has a cover body 41a and a shield 41b. The cover body 41a has a rectangular shape, is made of a translucent plastic whose main component is polycarbonate, and is therefore translucent from a front surface 410 to a rear surface 411. As shown in Fig. 1, the front surface 410 serves as the front surface of the vehicle solar panel 50, that is, as the design surface of the vehicle solar panel 50. As shown in Fig. As shown in Fig. 4, the cover body 41a and thus the protective cover 41 are curved in a convex manner from the rear surface 411 toward the front surface 410 in advance with a curvature that matches the roof panel of the vehicle. The shield 41b is made of a plastic whose main component is opaque (e.g., black) polycarbonate. The shield 41b is formed by injection molding it onto the rear surface 411 of the cover body 41 and is integrated with the rear surface 411. The cover body 41a and the shield 41b may be made of a plastic whose main component is not polycarbonate. Furthermore, the protective cover 41 may have only the cover body 41a.

[0029] The shield 41b has a peripheral portion 412 and coupling portions 413. The peripheral portion 412 surrounds the photovoltaic string 45 along the outer edge of the cover body 41a. The peripheral portion 412 prevents connecting flat wires 453 and the like of the photovoltaic string 45 from being seen from the front surface 410 of the cover body 41a. The coupling portions 413 are arranged on the inner side of the peripheral portion 412 and extend in the width direction of the cover body 41a. The coupling portions 413 prevent the equalizing lines 452 of the photovoltaic string 45 from being seen from the front surface 410.

[0030] One of the coupling portions 413, located at the center of the protective cover 41, is integrally provided with a first engagement projection 414. The first engagement projection 414 is located at the center of the protective cover 41 and thus at the center of the laminated body 40. The first engagement projection 414 extends straight downward from the coupling portion 413. At the peripheral portion 412, the front part of the protective cover 41 is integrally provided with a second engagement projection 415. The second engagement projection 415 has the same structure as the first engagement projection 414.

[0031] The back cover 43 is made of a plastic whose main component is polycarbonate. The back cover 43 has substantially the same size as the protective cover 41. The back cover 43 has a flat bottom plate 43a and a peripheral wall 43b extending upward from the bottom plate 43a while surrounding the bottom plate 43a. The bottom plate 43a has a through hole 430a through which the first engaging projection 414 is inserted, and a through hole 430b through which the second engaging projection 415 is inserted. The back cover 43a may be made of a plastic whose main component is not polycarbonate. The back cover 43 may have only the bottom plate 43a.

[0032] The photovoltaic string 45 has photovoltaic battery cells 451, balancing lines 452, and connecting flat wires 453. The photovoltaic battery cells 451 are arranged in a matrix. The photovoltaic battery cells 451 are electrically connected by the balancing lines 452 and the connecting flat wires 453.

[0033] The encapsulation 47 includes a first encapsulation member 47a and a second encapsulation member 47b. The first encapsulation member 47a and the second encapsulation member 47b are made of ethylene vinyl acetate (EVA) and have a plate shape. Furthermore, the first encapsulation member 47a includes a through-hole 471a through which the first engagement projection 414 is inserted, and a through-hole 471b through which the second engagement projection 415 is inserted. The second encapsulation member 47b includes a through-hole 472a through which the first engagement projection 414 is inserted, and a through-hole 472b through which the second engagement projection 415 is inserted. Instead of EVA, the first and second encapsulation components 47a, 47b can be made, for example, of an ionomer plastic, a silicone plastic, or a polyolefin. To facilitate understanding, Fig. 4 and the like illustrate the thicknesses and sizes of the first and second encapsulating members 47a, 47b of the photovoltaic battery cells and the like in an exaggerated manner, and illustrate the shapes of the first and second engaging protrusions 414, 415 and the like in an exaggerated manner.

[0034] In the laminated body 40, the protective cover 41, the first encapsulating member 47a, the photovoltaic string 45, the second encapsulating member 47b, and the back cover 43 are laminated in this order. Thus, the back cover 43 is arranged to face the rear surface 411 of the cover body 41a. In the laminated body 40, the protective cover 41 and the back cover 43 are temporarily held by bonding, for example, a double-sided adhesive tape, with the first encapsulating member 47a, the photovoltaic string 45, and the second encapsulating member 47b being disposed between the protective cover 41 and the back cover 43. This causes the first and second engaging protrusions 414, 415 to respectively extend through the through-holes 430a, 430b and protrude downward from the back cover 43.

[0035] The preparation step S1 includes the preparation of the laminating device 100, which is Fig. 2. The heater main bodies 5b are supplied with power to be heated. In this way, the heater 5 is used to heat the laminating jig 3 to a glass transition temperature of X2°C of the first and second encapsulating members 47a, 47b or higher. In the laminated body, the first and second encapsulating members 47a, 47b are made of EVA, whereas the protective cover 41 and the back cover 43 are made of a plastic whose main component is polycarbonate. Thus, as shown in Fig. 7, the glass transition temperature X2°C of the first and second encapsulating members 47a, 47b is lower than a glass transition temperature X1°C of the protective cover 41 and the back cover 43. As described below, in the laminated body 40, the protective cover 41 is located farther away from the laminating jig 3 than the back cover 43. Thus, even if the heat of the laminating jig 3 heats the laminated body 40, the temperatures of the protective cover 41 and the back cover 43 never reach the glass transition temperature X1°C at the same time. Accordingly, the heating device 5 heats the laminating jig 3 in a temperature range in which the back cover 43 can be heated to the glass transition temperature X1°C or higher by the heat of the laminating jig, whereas the temperature of the protective cover 41 can be set to be lower than the glass transition temperature X1°C.

[0036] The assembly step S2 is then carried out as described in Fig. 3. In the assembly step S2, as shown in Fig. 4 and Fig. 5, the laminated body 40 is mounted on the laminating jig 3. In the laminated body 40, the back cover 43 faces the laminating jig 3. As shown in Fig. 4, the first engaging protrusion 414 is inserted through the first engaging hole 31a, and the second engaging protrusion 415 is inserted through the second engaging hole 31b. Thus, the laminated body 40 is positioned relative to the laminating jig 3. This causes the bottom plate 43a of the back cover 43 to abut against the laminating jig 3, so that the laminating jig 3 supports the laminated body 40 to contact the back cover 43. When the laminated body 40 is mounted on the laminating jig 3, the first encapsulating member 47a, the photovoltaic string 45, the second encapsulating member 47b, and the back cover 43 are disposed between the protective cover 41 and the laminating jig 3. That is, the protective cover 41 is located further away from the laminating clamping device 3 than the protective cover 43.

[0037] Then the lamination step S3, which is described in Fig. 3. The lamination step S3 includes a preheating step S31 and a compression bonding step S32. In the preheating step S31, the laminated body 40 is heated for a certain period of time with the laminating jig 3 supporting the laminated body 40. This begins to gradually soften the back cover 43 and begins to deform the flat bottom plate 43a to conform to the shape of the support surface 310 (see FIG. Fig. 5). This also begins to gradually soften the first encapsulating member 47a and the second encapsulating member 47b. Since the laminating jig 3 is larger than the protective cover 41 and the back cover 43, even if the protective cover 41 and the back cover 43 thermally expand, the support surface 310 can support the laminated body 40. Furthermore, since the opening of the second engaging hole 31b is large, thermal expansion of the protective cover 41 allows the second engaging protrusion 415 to move in the second engaging hole 31b. Thus, after a certain period of time has elapsed, the preheating step S31 is completed.

[0038] After completion of the preheating step S31, the compression bonding step S32 is performed. In the compression bonding step S32, while the heat of the laminating jig 3 further heats the laminated body 40, the first and second pumps 13, 15 are activated, so that a vacuum state is created in the vacuum chamber 21, that is, in the first and second vacuum regions 21a, 21b, as shown in Fig. 6. This releases air from the laminated body 40. Subsequently, the second pump 15 is used to supply air to the second vacuum region 21b so that the second vacuum region 21b has a higher pressure than the first vacuum region 21a. This presses the diaphragm 7 onto the protective cover 41 of the laminated body 40 while elastically deforming the diaphragm 7. The laminating jig 3 further supports the laminated body 40 from a side where the protective cover 33 is provided, that is, from the side opposite to the diaphragm 7. In this way, the diaphragm 7 compression-bonds the laminated body 40 while the laminated body 40 is held with the laminating jig 3.

[0039] As the laminated body 40 is further heated by the heat of the laminating device 3, the temperature of the back cover 43 reaches or exceeds the glass transition temperature X1°C in the laminated body 40. This sufficiently softens the back cover 43. Thus, compression bonding of the laminated body 40 bends the back cover 43 and protrudes it toward the protective cover 41 along the support surface 310, so that the back cover 43 has a product shape. This also integrates the first encapsulating member 47a and the second encapsulating member 47b, which have been softened. Accordingly, the encapsulation 47 keeps the photovoltaic chain 45, ie, the photovoltaic battery cells 451, the compensating lines 452 and the connecting flat wires 453, in an encapsulated state between the protective cover 41 and the back cover 43.This integrates the protective cover 41, the back cover 43, the photovoltaic string 45 and the encapsulant 47. Thus, after completion of the compression bonding step S32 and the lamination step S3, the vehicle solar panel 50 shown in FIG. Fig. 1, from the laminated body 40. In the vehicle solar panel 50, portions of the first and second engagement projections 414, 415 projecting from the back cover 43 are cut away.

[0040] Thus, with this manufacturing method, in the laminated body 40 prepared by the preparation step S1, the protective cover 41 is curved in a convex manner from the back surface 411 toward the front surface 410. Accordingly, the laminating step S3 omits the curving of the protective cover 41. That is, with this manufacturing method, the protective cover 41 does not need to be heated and softened. Furthermore, in this manufacturing method, the mounting step S2 causes the back cover 43 to abut against the laminating jig 3, so that the laminated body 40 is mounted on the laminating jig 3. This moves the protective cover 41 away from the laminating jig 3.Thus, this manufacturing method prevents unnecessary heating of the protective cover 41 even if the laminated body 40 is heated by using the laminating jig 3 until the temperature of the back cover 43 reaches or exceeds the glass transition temperature X1°C. As a result, the temperature of the protective cover 41 never reaches the glass transition temperature X1°C. This will now be explained more specifically with reference to FIG. Fig. 7. In the graph, the lamination period is when the lamination step S3 is performed. From the start of the lamination step S3 until a time T1, specifically during a preheating period, the preheating step S31 is performed. From a time T1 to a time T2, specifically during a compression bonding period, the compression bonding step S32 is performed.

[0041] With the manufacturing method, heating is performed in the temperature range in which the back cover 43 can be heated to the glass transition temperature X1°C or higher by the heat of the laminating jig 3, whereas the temperature of the protective cover 41 can be set to be lower than the glass transition temperature X1°C. Thus, as the preheating period elapses, the laminated body 40 is heated by the laminating jig 3 such that a temperature of the protective cover 41 and the back cover 43 increases. Since the protective cover 41 is located farther away from the laminating jig 3 than the back cover 43, the temperature rise of the protective cover 41 is limited compared to the back cover 43. Subsequently, at a time t1, the preheating step S31 ends, and the compression bonding step S32 is started at the same time.As a result, a vacuum condition is created in the vacuum chamber 21 such that the membrane 7 abuts the laminated body 40. This slightly reduces the temperature of the protective cover 41 and the back cover 43 and thus the temperature of the laminated body 40.

[0042] While the compression bonding step S32 is being performed, the heat from the laminating jig 3 further heats the laminated body 40, so that the temperature of the back cover 43 exceeds the glass transition temperature X1°C. In contrast, the temperature of the protective cover 41 remains lower than the glass transition temperature X1°C throughout the entire period of the lamination step S3. Therefore, in this manufacturing method, although the front surface 410 of the cover body 41a abuts the membrane 7 in the protective cover 41, compression bonding of the laminated body 40 highly ensures that roughening of the front surface 410 is prevented. This manufacturing method also prevents roughening of the shield 41b of the protective cover 41.

[0043] In addition, this manufacturing method allows the back cover 43 to be heated to a glass transition temperature of X1°C or higher in the compression bonding step S32, and therefore to be bent by the lamination jig 3 in a preferential manner to achieve the product shape. Accordingly, this manufacturing method limits wrinkling of the back cover 43 and air entrapment between the back cover 43 and the encapsulant 47.

[0044] Thus, the method of manufacturing the solar panel according to the first embodiment allows manufacturing the vehicle solar panel 50 of high quality provided with the protective cover 41 and the back cover 43 made of a plastic. Second embodiment

[0045] In a manufacturing method according to a second embodiment, a laminating device 101, which is shown in Fig.8, in preparation step S1. In the laminating apparatus 101, a stepped portion 310a protrudes from the support surface 310 of the laminating jig 3 toward the laminated body 40. The shape of the stepped portion 310a may be changed. The remaining structures of the manufacturing method according to the second embodiment are the same as those of the manufacturing method according to the first embodiment, including the remaining structures of the laminating apparatus 101.

[0046] In this manufacturing method, the compression bonding step S32 is performed to curve the back cover 43 and protrude it toward the protective cover 41, and the shape of the stepped part 310a allows the bottom plate 43a of the back cover 43 to be provided with a step 43c. That is, in this manufacturing method, the back cover 43 has a product shape to have the step 43c while being curved in a convex manner toward the protective cover 41. Accordingly, the thickness of the vehicle solar panel 50 obtained by this manufacturing method changes at the step 43c. The remaining operations of the manufacturing method according to the second embodiment are the same as those of the manufacturing method according to the first embodiment.

[0047] The present invention has been described according to the first embodiment and the second embodiment. However, it should be apparent to those skilled in the art that the present invention may be embodied in many other specific forms without departing from the spirit or scope of the invention. In particular, it should be understood that the present invention may be embodied in the following forms.

[0048] For example, the support surface 310 may have a predetermined pattern so that the pattern of the support surface 310 is transferred to the bottom plate 43a of the back cover 43 in the compression bonding step S32.

[0049] The present invention is applicable to a manufacture of solar panels or the like used for various types of photovoltaic devices in addition to vehicle solar panels.

Claims

[1] A method for manufacturing a solar panel (50), the method comprising the following steps: Preparing a laminated body (40) which a protective cover (41) made of plastic which is translucent from a front surface (410) to a rear surface (411) and which is curved in a convex manner from the rear surface (411) towards the front surface (410), a flat rear cover (43) made of plastic arranged to face the rear surface (411) of the protective cover (41), a photovoltaic battery cell (451), and an encapsulation (47) that holds the photovoltaic battery cell (451) in an encapsulated state between the protective cover (41) and the back cover (43); Mounting the laminated body (40) on a laminating jig (3) such that the back cover (43) abuts the laminating jig (3); and Heating the laminated body (40) with the laminating jig (3) until a temperature of the back cover (43) reaches or exceeds a glass transition temperature, and compression bonding the laminated body (40) by holding the laminated body (40) between a membrane (7) and the laminating jig (3), whereby a solar panel (50) is obtained from the laminated body (40), wherein the laminating jig (3) is curved in a convex manner towards the laminated body (40), whereby the procedure characterized by is that mounting the laminated body (40) on the laminating jig (3) comprises mounting the laminated body (40) on a support surface (310) of the laminating jig (3) which is curved in a convex manner, the protective cover (41) has one or more engaging projections (414, 415) extending from the rear surface (411) to the laminating chuck (3), each of the back cover (43) and the encapsulation (47) has one or more through holes (430a, 430b, 471a, 471b, 472a, 472b) through which the one or more engagement projections (414, 415) are inserted, the laminating clamping device (3) has one or more engagement holes (31a, 31b), and mounting the laminated body (40) on the laminating jig (3) comprises positioning the laminated body (40) relative to the support surface (310) by appropriately inserting the one or more engagement projections (414, 415) into the one or more through holes (430a, 430b, 471a, 471b, 472a, 472b) and into the one or more engagement holes (31a, 31b). [2] The method according to claim 1, wherein compression bonding of the laminated body (40) comprises heating the laminated body (40) such that the temperature of the protective cover (41) is lower than the glass transition temperature.

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