Sealing device

Abstract

To provide a sealing device capable of making the way of pressing a substrate end face uniform with time and on both substrate end faces as compared with a conventional one.SOLUTION: Melting and curing a sealing material to seal a laminated panel in which the sealing material is sandwiched between a first substrate and a second substrate, the laminated panel having a first side and a second side in a plan view, A first side pressing portion that extends along the first side and presses a first end surface to which the first side of the laminated panel belongs, a second side pressing portion that extends along the second side and presses a second end surface to which the second side of the laminated panel belongs, a drawing unit that draws the first side pressing portion and the second side pressing portion to a center side of the laminated panel, and a melting and curing mechanism that cures the sealing material in a state where the first side pressing portion is in contact with the first end surface and the second side pressing portion is in contact with the second end surface by the drawing unit.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a sealing device for sealing laminated panels, which is used in the manufacturing process of laminated panels. [Background technology]

[0002] A laminated panel is known in which a functional layer is sandwiched between a first substrate and a second substrate via a sealing material. Examples of laminated panels with this structure include solar cell modules, which have been widely manufactured in recent years. In this type of laminated panel, the first substrate and the second substrate are integrated with the functional layer sandwiched between them. Furthermore, the manufacturing method of the above-mentioned laminated panel is being improved day by day. For example, Patent Document 1 discloses a method for manufacturing a liquid crystal device by disposing a liquid crystal cell between first and second transparent substrates. The manufacturing method disclosed in Patent Document 1 aims to reduce breakage of transparent substrates, and when integrating a liquid crystal cell between a first transparent substrate and a second transparent substrate having a smaller outer shape than the first transparent substrate, the first transparent substrate is placed on a buffer member placed outside the second transparent substrate so as to be spaced apart from and facing the liquid crystal cell stacked on the second transparent substrate, the buffer member is contracted, and the first transparent substrate, liquid crystal cell, and second transparent substrate are integrated. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Publication No. 2023-028885 Summary of the Invention [Problem to be solved by the invention]

[0004] In Patent Document 1, a cushioning member arranged outside a second transparent substrate, which has a smaller outer shape than a first transparent substrate, is contracted to integrate the first transparent substrate and the second transparent substrate, which is considered to be an effective technique when integrating substrates with different outer shapes. On the other hand, many laminated panels are made by integrating substrates with almost identical outer shapes, aligning their edge surfaces to the same plane. In such identical laminated panels, in order to ensure the same plane, it is common to integrate the first and second substrates with their edge surfaces aligned.

[0005] Another problem is that when the first and second substrates are integrated, the sealant sandwiched between them may melt and flow out. In a laminated panel using irregularly shaped substrates such as those in Patent Document 1, the sealant melts and flows out from between the two substrates in a direction toward the inside and outside of the substrate plane. In contrast, in a commonly used laminated panel using first and second substrates of the same size, the direction in which the sealant melts and flows is the normal to the edge faces of both substrates, which is a direction determined by the sealing device, not by the laminated panel itself. Therefore, in a laminated panel using first and second substrates of the same size, depending on how the laminated panel is arranged in the sealing device, the edge faces of both substrates are pressed unevenly over time and around the entire periphery of the edge faces of both substrates, which can lead to a decrease in yield and an increase in the number of steps required for inspection and repair.

[0006] Therefore, an object of the present invention is to provide a sealing device that can make the pressing of the substrate end faces uniform over time and on both substrate end faces, compared to conventional devices. [Means for solving the problem]

[0007] One aspect of the present invention for solving the above-mentioned problems is a sealing device that melts and hardens a sealing material to seal a laminated panel sandwiched between a first substrate and a second substrate, the laminated panel having a first side and a second side when viewed in a plane, the sealing device comprising: a first side pressing portion that extends along the first side and presses a first end face of the laminated panel to which the first side belongs; a second side pressing portion that extends along the second side and presses a second end face of the laminated panel to which the second side belongs; retraction means that retracts the first side pressing portion and the second side pressing portion toward the center of the laminated panel; and a melting and hardening mechanism that hardens the sealing material when the retraction means brings the first side pressing portion into contact with the first end face and the second side pressing portion into contact with the second end face.

[0008] According to this aspect, the first edge pressing portion is in contact with the first end face, and the second edge pressing portion is in contact with the second end face, and thus, compared to the prior art, the pressing of the substrate end faces becomes uniform over time and on both substrate end faces, at least at the first end face and the second end face.

[0009] In a preferred aspect, the first side of the laminated panel faces the second side when viewed in plan.

[0010] According to this aspect, the opposing end faces can be pressed equally, so that the entire laminated panel can be uniformly integrated.

[0011] In a preferred aspect, as the retraction is performed by the retraction means, the first edge pressing portion presses a major portion of the first end surface, and the second edge pressing portion presses a major portion of the second end surface.

[0012] According to this aspect, pressing can be performed uniformly even within the edge.

[0013] A preferred aspect is a second retraction means for retracting the second edge pressing portion toward the first edge pressing portion, and the melting and hardening mechanism retracts the first edge pressing portion toward the second edge pressing portion by the retraction means, and further melts and hardens the sealing material in a state in which the second edge pressing portion is retracted toward the first edge pressing portion by the second retraction means.

[0014] According to this aspect, even a large-area laminated panel can be pressed uniformly.

[0015] In a preferred aspect, the laminated panel has a third edge connecting the first edge and the second edge when viewed in a plan view, the retraction means has a third edge pressing portion extending along the third edge and pressing a third end face of the laminated panel to which the third edge belongs, and the melting and hardening mechanism melts and hardens the sealing material in a state in which the first edge pressing portion presses the first end face, the second edge pressing portion presses the second end face, and the third edge pressing portion presses the third end face.

[0016] According to this aspect, the edge pressing mechanism has a third edge pressing portion, and can press even a laminated panel having adjacent edges uniformly.

[0017] A preferred aspect is a laminated panel having a plurality of edge pressing members, each edge pressing member having an edge pressing portion, the laminated panel having a polygonal shape when viewed in a plane, and the edge pressing members retract so that the edge pressing portions of adjacent edge pressing members come into contact with the laminated panel.

[0018] According to this aspect, even a polygonal laminated panel can be pressed uniformly.

[0019] A preferred aspect is one in which the sealing material is heated, melted, and hardened by pressing the sheet portion across the first substrate of the laminated panel from the outside of the first edge pressing member via the first edge pressing member when viewed in a plane, and the first edge pressing member has rounded corners on the sheet portion side and opposite the laminated panel.

[0020] According to this aspect, the sheet portion is not damaged even when used repeatedly.

[0021] One aspect of the present invention is a sealing device that melts and hardens the sealing material of a laminated panel in which a first substrate, a sheet-like sealing material, and a second substrate are stacked in this order, and seals the laminated panel.The laminated panel is such that the main surface of the first substrate and the main surfaces of the second substrate are the same shape, and each end face of the first substrate and each end face of the second substrate are aligned to be flat.The sealing device melts and hardens the sealing material using a melting and hardening mechanism that melts and hardens the sealing material while pressing the flat surface using a pressing mechanism that presses around the entire periphery. [Effects of the Invention]

[0022] According to the sealing device of the present invention, the pressing of the substrate end faces is more uniform over time and on both substrate end faces than in the conventional device. [Brief explanation of the drawings]

[0023] [Figure 1] 1 is a cross-sectional view showing an overview of an embodiment of a sealing device of the present invention. [Figure 2] 2A and 2B are perspective views of the edge pressing mechanism of the sealing device shown in FIG. 1, in which (a) shows a state in which the diameter is reduced in an operating state, and (b) shows a state in which the diameter is increased in an inoperating state. [Figure 3] FIG. 3 is an exploded partial perspective view of a part of the edge pressing mechanism of FIG. 2. [Figure 4]10A and 10B are enlarged perspective views of a corner portion of the edge pressing mechanism, in which FIG. 10A shows a state in which the diameter is reduced in an operating state, and FIG. 10B shows a state in which the diameter is increased in an inoperating state. [Figure 5] 10(a) to 10(c) are perspective views showing the process of attaching an edge pressing mechanism to a laminated panel workpiece. [Figure 6] FIG. 2(a) is a perspective view of a laminated panel, and FIG. 2(b) is an enlarged cross-sectional view showing the layer structure of the laminated panel. [Figure 7] 1 is a perspective view of a solar cell module (laminated panel) according to the present invention. [Figure 8] 8 is a cross-sectional view of the solar cell module of FIG. 7 taken along line AA, and for ease of understanding, hatching of the first light-receiving-side sealing material and the first back-surface-side sealing material has been omitted. DETAILED DESCRIPTION OF THE INVENTION

[0024] Hereinafter, embodiments of the present invention will be described in detail. FIG. 1 is a schematic diagram of an entire embodiment of a sealing device 1 of the present invention. The sealing device 1 shown in FIG. 1 is used in the process of manufacturing a laminated panel 2 as shown in FIG. The laminated panel 2 has a rectangular shape in a plan view and is surrounded by two long sides 5, 6 and two short sides 7, 8. In this embodiment, the long sides are referred to as the first side 5 and the second side 6, and the short sides are referred to as the third side 7 and the fourth side 8. The outer end face of the first side 5 is referred to as the first end face 85, the outer end face of the second side 6 is referred to as the second end face 86, the outer end face of the third side 7 is referred to as the third end face 87, and the outer end face of the fourth side 8 is referred to as the fourth end face 88.

[0025] The laminated panel 2 has a functional layer 20 sandwiched between a first substrate 10 and a second substrate 11 with sealing materials 15 and 16 interposed therebetween. The sealing materials 15 and 16 are made from thermoplastic sheets 21, 22, 23, and 25, and are formed by melting and re-hardening the thermoplastic sheets 21, 22, 23, and 25. That is, in the laminated panel 2, the front-side sealing material 15 formed by melting and re-hardening the thermoplastic sheets 21 and 22 is located between the first substrate 10 and the functional layer 20, and the back-side sealing material 16 formed by melting and re-hardening the thermoplastic sheets 23 and 25 is located between the functional layer 20 and the second substrate 11. The laminated panel 2 has a front sealing material 15 and a back sealing material 16 sandwiched between a first substrate 10 and a second substrate 11.

[0026] (Sealing device 1) The sealing device 1 of this embodiment is a device that seals the laminated panel 2 by melting and hardening the sealing material (thermoplastic sheets 21, 22, 23, 25). As shown in FIG. 1, the sealing device 1 includes a side pressing mechanism 30 and a melting and hardening mechanism 31, and preferably further includes a sheet portion 32.

[0027] (Edge pressing mechanism 30) 2, the edge pressing mechanism 30 is a rectangular frame having four sides 45, 46, 47, and 48. Each of the sides 45, 46, 47, and 48 of the edge pressing mechanism 30 functions as an edge pressing member that abuts against and presses each of the sides of the laminated panel 2, namely, a first side 5, a second side 6, a third side 7, and a fourth side 8. In this embodiment, the names of the components constituting each side 45, 46, 47, 48 of the edge pressing mechanism 30 are referred to as the first edge pressing member 45, the second edge pressing member 46, the third edge pressing member 47, and the fourth edge pressing member 48, in accordance with the names of each side of the laminated panel 2. 2 and 3, the side pressing mechanism 30 is equipped with a retraction means 50, and each of the side pressing members 45, 46, 47, 48 is biased in the overall diameter-reducing direction. In the side pressing mechanism 30, the first side pressing member 45, the second side pressing member 46, the third side pressing member 47, and the fourth side pressing member 48 are biased in the direction of the arrow in FIG. 2(b) by the retraction means 50. The edge pressing mechanism 30 of this embodiment includes a first edge pressing member 45, a second edge pressing member 46, a third edge pressing member 47, a fourth edge pressing member 48, and retraction means 50 attached to the connection portions of the edge pressing members 45, 46, 47, and 48. The edge pressing mechanism 30 of this embodiment is a jig for the sealing process that is applied to the laminated panel 2 before it is subjected to the sealing process, continues to be applied during the process, and is removed from the laminated panel 2 after the process.

[0028] (Edge pressing member) The edge pressing members 45, 46, 47, and 48 correspond to the edges 5, 6, 7, and 8 of the laminated panel 2. For example, the first edge pressing member 45 corresponding to the first edge 5 of the laminated panel 2 comes into contact with the edge face (first end face 85) of the first edge 5 of the laminated panel 2 and presses the entire edge face of the first edge 5 of the laminated panel 2. The same is true for the second edge pressing member 46, the third edge pressing member 47, and the fourth edge pressing member 48, which come into contact with the edge face (second end face 86) of the second edge 6, the edge face (third end face 87) of the third edge 7, and the edge face (fourth end face 88) of the fourth edge 8 of the laminated panel 2, respectively, and press the entire edge face of each edge of the laminated panel 2.

[0029] Each of the side pressing members 45, 46, 47, and 48 is made up of two rod members connected in a straight line. Each rod member has a rectangular cross section. One end of each of the side pressing members 45, 46, 47, and 48 has a protruding guide 26 and a retraction means mounting seat 27. The other end of each of the side pressing members 45, 46, 47, and 48 has a guide sliding portion 28 and a retraction means mounting seat 33.

[0030] The edge pressing members 45, 46, 47, 48 are components of the edge pressing mechanism 30, and preferably have edge pressing portions 55, 56, 57, 58 that contact the outer end faces (first end face 85, second end face 86, third end face 87, fourth end face 88) of each edge 5, 6, 7, 8 of the laminated panel 2. In this embodiment, the cross-sectional shape of the side pressing members 45, 46, 47, and 48 is quadrangular, and the inner surfaces of the side pressing members 45, 46, 47, and 48 function as side pressing portions 55, 56, 57, and 58, respectively. For example, the first-side pressing member 45 has a first-side pressing portion 55 that contacts the outer end surface (first end surface 85 ) of the first side 5 of the laminated panel 2 .

[0031] The thickness of the edge pressing members 45, 46, 47, 48 is preferably slightly thicker than the thickness of the laminated panel 2 after the sealing materials 15, 16 have hardened. In other words, the thickness is preferably within a range of 0 to 1 mm greater than the thickness from the outer surface of the first substrate 10 to the outer surface of the second substrate 11, which is the thickness of the laminated panel 2 after the sealing step.

[0032] The edge pressing members 45 , 46 , 47 , and 48 in the edge pressing mechanism 30 are preferably arranged parallel to the edges 5 , 6 , 7 , and 8 of the laminated panel 2 . The length of each of the side pressing members 45 , 46 , 47 , 48 is preferably approximately the same as the length of the corresponding side of the laminated panel 2 .

[0033] The materials for the side pressing members 45, 46, 47, 48 can be any material that has a certain level of rigidity even when heated to melt the seal according to the present invention. The material forming the side pressing members 45, 46, 47, 48 is preferably selected from the group consisting of metal, especially aluminum or copper, SUS, heat-resistant resin, and carbon material.

[0034] (Retraction means 50) Each of the side pressing members 45, 46, 47, and 48 is framed in a rectangular shape. The adjacent side pressing members 45, 46, 47, 48 are connected with a certain degree of freedom in the longitudinal direction. The protruding guide 26 of each side pressing member 45, 46, 47, 48 is engaged with the guide sliding portion 28 of the adjacent side pressing member 45, 46, 47, 48. Further, retraction means 50 are provided between adjacent side pressing members 45, 46, 47, and 48.

[0035] The retraction means 50 is a member that retracts the side pressing members 45, 46, 47, 48, and retracts the side pressing portions 55, 56, 57, 58 formed by the inner surfaces thereof toward the center of the surface of the laminated panel 2. The retraction means 50 preferably includes at least a first retraction means 50 that retracts one end of the first edge pressing portion 55 toward the second edge pressing portion 56, and a second retraction means 50 that retracts one end of the second edge pressing portion 56 toward the first edge pressing portion 55. It is preferable that the retraction means 50 includes a third retraction means 50 that retracts one end of the third edge pressing portion 57 toward the fourth edge pressing portion 58, and it is more preferable that the retraction means 50 includes a fourth retraction means 50 that retracts one end of the fourth edge pressing portion 58 toward the third edge pressing portion 57. It is more preferable that the retracting means 50 retracts both of the side pressing portions 55 , 56 , 57 , 58 of the adjacent side pressing members 45 , 46 , 47 , 48 so as to come into contact with the laminated panel 2 .

[0036] The material used for exerting the retraction force of the retraction means 50 can be any elastic body that can maintain the elasticity required to generate the retraction force when heated to melt the seal of the present invention or when pressurized to seal. The material of the retraction means 50 is preferably a metallic elastic body or a rubber elastic body, and a metallic spring is more preferable because it can be used repeatedly.

[0037] In such a side pressing mechanism 30, it is preferable that each side pressing portion 55, 56, 57, 58 is retracted by a retraction means 50 provided between adjacent side pressing members 45, 46, 47, 48, as shown in FIG. It is more preferable that the edge pressing mechanism 30 be balanced so that the sum of the vectors consisting of the pulling force and direction throughout the entire edge pressing mechanism 30 forms a point, and by doing so, a highly reliable laminated panel 2 can be produced. In Figure 2, (b) shows the edge pressing mechanism 30 in a state where retraction by the retraction means 50 has not been performed, specifically, for example, where the spring is extended, i.e., where the edge pressing mechanism 30 is in a non-operating state, and the laminated panel 2 has not been taken into the edge pressing mechanism 30, and the arrow indicates the retraction direction, specifically, for example, the direction in which the spring contracts. In Figure 2, (a) shows the edge pressing mechanism 30 in an operating state, in which retraction is being performed by the retraction means 50, specifically, for example, when the spring is compressed, and the laminated panel 2 is taken into the edge pressing mechanism 30.

[0038] Furthermore, to enable this retraction function during the sealing process, it is necessary that the adjacent crossing side pressing members 45, 46, 47, 48 are movable relative to each other. Such movement is achieved by connecting each side pressing member 45, 46, 47, 48 to the adjacent side pressing member 45, 46, 47, 48 via the retraction means 50, and it is also desirable to restrict each side pressing member 45, 46, 47, 48 to move in the axial direction. Conversely, it is desirable to restrict one side pressing member 45, 46, 47, 48 to move in a direction perpendicular to the adjacent side pressing member 45, 46, 47, 48. In this embodiment, this movement is ensured by the engagement between the protruding guide 26 and the guide sliding portion 28.

[0039] As another measure, an elongated hole extending in the longitudinal direction of the side pressing members 45, 46, 47, 48 may be formed at one end of each of the side pressing members 45, 46, 47, 48, and a connecting protrusion provided on an adjacent side pressing member 45, 46, 47, 48 may be engaged in the elongated hole. According to this embodiment, at the connection portion of each side pressing member 45, 46, 47, 48, the connecting protrusion moves in the longitudinal direction within the elongated hole, thereby moving each side pressing member 45, 46, 47, 48 in the axial direction and shortening the distance between the opposing side pressing members 45, 46, 47, 48, making it possible to stably seal the end faces (first end face 85, second end face 86, third end face 87, fourth end face 88) of the laminated panel 2. 2, in order to press the laminated panel 2 from its entire periphery, the sum of the vectors in the retraction direction of the retraction means 50 must be 0 for the entire laminated panel 2. For example, if the laminated panel 2 is square, the vectors in the retraction direction of adjacent retraction means 50 must be perpendicular to each other, and the perpendicular directions must be the same for the entire laminated panel 2.

[0040] The corners of the side pressing portions 55, 56, 57, and 58 on the side of the sheet portion 32 are desirably rounded. That is, it is preferable that the corners on the side of the sheet portion 32 have an R. The rounded corners that are part of the side pressing portions 55, 56, 57, and 58 come into contact with the sheet portion 32, and therefore are less likely to damage the sheet portion 32.

[0041] (seat part 32) The sheet portion 32 is a member that mediates the pressure and heat exerted on the laminated panel 2 from the melting and hardening mechanism 31 when the seal of the present invention is melted and hardened, and it ensures that these are transmitted evenly to the laminated panel 2, and also has the function of enabling the laminated panel 2 and the edge pressing mechanism 30 to be easily removed from the melting and hardening mechanism 31 after sealing.

[0042] The sheet portion 32 preferably covers the first substrate 10 side. Specifically, when viewed in a plan view, the sheet portion 32 is pressed against the first substrate 10 of the laminated panel 2 from the outside of the first edge pressing member 45 via the first edge pressing member 45, and the heating for sealing is performed.

[0043] (Melting and hardening mechanism 31) The melting and hardening mechanism 31 is a mechanism that applies pressure and heat to the laminated panel 2 during melting and hardening of the seal according to the present invention. Specifically, the melt-set mechanism 31 can exert an enveloping and compressive pressure on the laminate panel 2 disposed therein at room temperature. The melting and hardening mechanism 31 can also heat and melt the sealing materials 15 and 16 . Furthermore, the melting and hardening mechanism 31 can cool the inside so that the laminated panel 2 or the like can be taken out at room temperature. In this way, the melting and hardening mechanism 31 is a device that can supply and release heat so that the sealing materials 15, 16 can be heated to soften them, and can be cooled to make the laminated panel 2 removable.

[0044] Any device can be used as the melting and hardening mechanism 31 as long as it is a mechanism capable of melting and hardening the seal according to the present invention, and a preferred example is the vacuum thermocompression bonding device shown in FIG.

[0045] FIG. 1 is a schematic cross-sectional view of a vacuum laminator, which is an example of a vacuum thermocompression device. The vacuum laminator includes a lower container 70 and an upper container 71, which are detachable from each other via an airtight seal (not shown). The lower container 70 and the upper container 71 include intake and exhaust ports 72 and 73, respectively, and the upper container 71 also includes a diaphragm 75 made of synthetic rubber.

[0046] A mounting table 76 incorporating a heater is provided inside the lower container 70. The mounting table 76 acts as a heating plate that heats the laminated panel 2 to melt the sealing materials 15, 16.

[0047] (Sealing process) Next, a sealing process for the laminated panel 2 using the sealing device 1 of this embodiment will be described. In this embodiment, as shown in Fig. 5(a), the laminated panel 2 is placed on a mounting table 76 that has been heated to a predetermined temperature in advance. Note that the laminated panel 2 here is a work in progress before being sealed. Then, a side pressing mechanism 30 is attached to the laminated panel 2. 5(b), an operator manually biases the side pressing portions 55, 56, 57, and 58 of the side pressing mechanism 30 in the direction away from each other, and the side pressing portions 55, 56, 57, and 58 spread, causing the side pressing mechanism 30 to expand in diameter and surround the periphery of the laminated panel 2. When the operator releases his / her hand, the spring force of the retraction means 50 moves the side pressing portions 55, 56, 57, and 58, causing the side pressing mechanism 30 to contract in diameter, as shown in FIG.

[0048] The sealing device 1 of this embodiment is characterized in that the sealing is performed in a state in which the first side pressing portion 55 is retracted toward the second side pressing portion 56 by the retraction means 50, specifically the first retraction means 50a. The sealing device 1 of this embodiment preferably seals the end face (first end face 85) of the laminated panel 2 with the second edge pressing portion 56 retracted toward the first edge pressing portion 55 by the second retraction means 50b, and more preferably seals the end face of the laminated panel 2 with the first edge pressing portion 55 contacting and pressing a majority of the first end face 85 of the first edge 5 of the laminated panel 2 and the second edge pressing portion 56 contacting and pressing a majority of the end face (second end face 86) of the second edge 6 of the laminated panel 2. The sealing device 1 of this embodiment seals the laminated panel 2 with the first edge pressing portion 55 contacting and pressing a majority of the first end face 85 of the first edge 5 of the laminated panel 2, the second edge pressing portion 56 contacting and pressing a majority of the second end face 86 of the second edge 6 of the laminated panel 2, and the third edge pressing portion 57 contacting and pressing a majority of the end face (third end face 87) of the third edge 7 of the laminated panel 2. It is even more preferable that the fourth edge pressing portion 58 contacts and presses a majority of the end face (fourth end face 88) of the fourth edge 8 of the laminated panel 2.

[0049] In this state, the lower container 70 and the upper container 71 are joined via an airtight seal (not shown), and the inside of the lower container 70 is evacuated via the intake / exhaust port 72 by a rotary pump (not shown).

[0050] The sealing materials 15, 16 are heated by the mounting table 76, which has been heated to a predetermined temperature by a built-in heater, and the sealing materials 15, 16 soften and melt. At this point, atmospheric pressure is introduced into the upper container 71 via the intake / exhaust port 73, and the diaphragm 75 presses the laminated panel 2 from above, via the sheet portion 32, with the atmospheric pressure, generally uniformly across the surface. In this state, the laminated panel 2 is cooled. During this heating and cooling process, the sealing materials 15, 16 melt and harden. The hardening of the sealing materials 15, 16 occurs within the first substrate 10 and the second substrate 11.

[0051] When sealing the laminated panel 2, for example, if a vacuum heat pressing device, such as a vacuum laminator as shown in Figure 1, is used as the preferred melting and hardening mechanism 31 of the present invention, the edge pressing members 45, 46, 47, 48 will be arranged around the laminated panel 2 placed on the mounting table 76 of the vacuum laminator as edge pressing members 45, 46, 47, 48 of a predetermined thickness. Then, one of the containers of the vacuum laminator, for example the lower container 70, is evacuated, and the sealing materials 15, 16 are melted while the diaphragm 75 inside the laminator presses the laminated panel 2, causing the sealing materials 15, 16 to harden in that state.

[0052] The reason why a vacuum laminator is preferably used as a sealing means is to prevent the generation of air bubbles within the laminated panel 2. In other words, if air bubbles remain or are mixed in at the boundaries or inside the sealing materials 15, 16, this could reduce the reliability of the laminated panel 2. Because a vacuum laminator degasses during sealing, there is little risk of air bubbles remaining or being mixed in at the boundaries or inside the sealing materials 15, 16 before and after melting, and a highly reliable laminated panel 2 can be completed.

[0053] The diaphragm 75 of the vacuum laminator preferably presses the laminate panel 2 with a pressure in the range of 0.02 MPa to atmospheric pressure.

[0054] The heating temperature of the mounting table 76 in the melting and hardening process according to the present invention can be set, for example, to a maximum temperature of 165° C., and the temperature can be preferably set within a range of 160 to 180° C. If the set temperature is high, the sealing materials 15, 16 will melt quickly and hardening will also progress quickly, and conversely, if the set temperature is low, the melting and hardening of the sealing materials 15, 16 can be delayed.

[0055] (Laminated Panel 2) Next, a description will be given of the laminated panel 2 that is recommended to be manufactured by the sealing device 1 of this embodiment. Fig. 7 is a perspective view of the laminated panel 2 (solar cell module 100) according to the present invention. The laminated panel 2 according to this embodiment is preferably a solar cell module 100 including a solar cell structure 110, in which sealing materials 15 and 16 are sandwiched between a first substrate 10 and a second substrate 11.

[0056] Furthermore, the laminated panel 2 is a panel that includes the sealing step according to the present invention as part of its manufacturing process, from before to after manufacturing.

[0057] When the laminated panel 2 is a solar cell module 100, for example, the first substrate 10 is a light-receiving-side sealing substrate that serves as a substrate on the light-receiving surface 150 side of the panel, and the second substrate 11 is a back-side sealing substrate that serves as a substrate on the back surface 151 side of the panel. That is, the laminated panel 2 is preferably a solar cell module 100, and in that case, it is a plate-like panel whose first main surface serves as the light-receiving surface 150 and whose second main surface serves as the back surface 151, as shown in FIG.

[0058] The laminated panel 2 includes at least a first side 5 and a second side 6 when viewed in a plan view. Here, a side is a part of a line segment or an arc. When viewed in a plane, the laminated panel 2 preferably has a first side 5 facing the second side 6, more preferably includes a third side 7 connecting the first side 5 and the second side 6, and further preferably has a polygonal shape. When viewed from above, the laminated panel 2 is preferably quadrangular, more preferably square, and particularly preferably rectangular. The laminated panel 2 extends along the sides 5, 6, 7, and 8, and has end faces corresponding to the sides 5, 6, 7, and 8. That is, the laminated panel 2 has a first end face 85, a second end face 86, a third end face 87, and a fourth end face 88.

[0059] (Solar cell module 100) As shown in FIG. 7 , the solar cell module 100 preferably includes a light-receiving-side sealing material 102 that is a part of the sealing material 105, a solar cell structure 110 that includes solar cell strings 106 (106a to 106f) and wiring members 107, and a back-side sealing material 120 that is also a part of the sealing material 105. In this case, the solar cell strings 106 and the wiring members 107 are sandwiched and sealed between the light-receiving-side sealing material 102 and the back-side sealing material 120.

[0060] The solar cell module 100 is capable of generating electricity in the solar cell strings 106 inside when light is incident on the light-receiving surface 150. It is preferable that the solar cell module 100 has a wiring shielding member 13 provided on the light-receiving-side sealing material 102, and that the wiring member 107 is partially or entirely hidden by the wiring shielding member 13. As shown in FIG. 7, the solar cell module 100 (laminated panel 2) has a plurality of solar cell strings 106 (106a to 106f) arranged side by side in the lateral direction X at intervals.

[0061] (First board 10) The first substrate 10 is a light-transmitting insulating substrate that has sealing properties, insulating properties, and light-transmitting properties, and is a light-receiving-side sealing substrate that constitutes the light-receiving surface 150.

[0062] The first substrate 10 is not particularly limited as long as it has sealing, insulating, and light-transmitting properties, and for example, a glass substrate such as float glass or colored glass can be used.

[0063] (Sealant 105) The sealing material 105 is in sheet form before use, and is an insulating sealing material with sealing and insulating properties.It is an adhesive that bonds the first substrate 10 and the second substrate 11 to the solar cell structure 110, and melts when heated, and hardens and solidifies after cooling to room temperature. The sealing material 105 is not particularly limited as long as it has sealing properties, insulating properties, and, if necessary, light-transmitting properties. For example, a resin sealing material such as polyolefin elastomer can be used, and preferably contains a cross-linking agent that can be cross-linked by heating.

[0064] (Light-receiving side sealing material 102) The light-receiving-side sealing material 102 is used on the light-receiving surface 150 side of the sealing material 105 used in the solar cell module 100, and in addition to having the material properties of a sealing material, has light-transmitting properties and bonds between the first substrate 10 and the solar cell structure 110.

[0065] The light-receiving-side sealing material 102 covers the light-receiving surface 150 side of the solar cell string 106 that mainly constitutes the solar cell structure 110 . The light-receiving-side encapsulant 102 preferably includes a first light-receiving-side encapsulant 521 and a second light-receiving-side encapsulant 522 in this order from the solar cell structure 110 toward the first substrate 10 .

[0066] The first light-receiving-side sealing material 521 has elasticity and is capable of deforming along the solar cell strings 106 and the wiring members 107, thereby burying parts of the solar cell strings 106 and the wiring members 107.

[0067] The first light-receiving side sealing material 521 is not particularly limited as long as it has sealing, insulating, and light-transmitting properties, and for example, a resin sealing material such as polyolefin elastomer can be used.

[0068] The second light-receiving side sealing material 522 is a light-transmitting insulating sealing material that has sealing properties, insulating properties, and light-transmitting properties, and is an adhesive material that bonds the first light-receiving side sealing material 521 and the first substrate 10 together.

[0069] The second light-receiving side sealing material 522 is not particularly limited as long as it has sealing, insulating, and light-transmitting properties, and for example, a resin sealing material such as polyolefin elastomer can be used.

[0070] (Solar cell string 106) As shown in FIG. 8, the solar cell string 106 is formed by electrically connecting one or more solar cell cells 40 in series directly or via a conductive adhesive 41.

[0071] The solar cell 40 has a negative electrode terminal 42 provided on one main surface and a positive electrode terminal 43 provided on the other main surface.

[0072] Furthermore, when viewed in a plane, the solar cell 40 is a small rectangular panel having two opposing sides 144, 145, with the negative terminal portion 42 provided along one side 144 in the vicinity thereof, and the positive terminal portion 43 provided along the opposite side 145 in the vicinity thereof.

[0073] In the solar cell string 106 of this embodiment, the negative electrode terminal portions 42 and positive electrode terminal portions 43 of adjacent solar cells 40, 40 are connected together at overlapping portions (so-called shingled connection). In the solar cell string 106 of this embodiment, the solar cells 40 are arranged in a vertical direction Y (a direction perpendicular to the horizontal direction X).

[0074] The conductive adhesive 41 is a conductive member having electrical conductivity, and is an adhesive that connects the terminal portions 42, 43 of the adjacent solar cells 40, 40 together. The conductive adhesive 41 of this embodiment is a conductive paste.

[0075] (Wiring member 107) The wiring member 107 is a member for extracting electric power from each solar cell string 106 to the outside.

[0076] (rear surface sealing material 120) As shown in FIG. 7, the back surface-side sealing material 120 covers the back surface 151 side of the solar cell string 106, and preferably includes a first back surface-side sealing material 531 and a second back surface-side sealing material 532.

[0077] The first back surface side sealing material 531 is an insulating sealing material that has sealing and insulating properties, and is an adhesive material that bonds the solar cell strings 106 and wiring members 107 to the second back surface side sealing material 532, as shown in Figure 8.

[0078] The first back surface side sealing material 531 is elastic and can deform along the solar cell strings 106 and the wiring members 107, thereby burying the solar cell strings 106 and the wiring members 107 together with the first light-receiving side sealing material 521.

[0079] There are no particular limitations on the first rear surface side sealing material 531 as long as it has sealing and insulating properties, and for example, a resin sealing material such as polyolefin elastomer can be used.

[0080] The second rear surface side sealing material 532 is an insulating sealing material that has sealing and insulating properties, and is an adhesive material that bonds the first rear surface side sealing material 531 and the second substrate 11 together, as shown in FIG.

[0081] There are no particular limitations on the second rear surface side sealing material 532 as long as it has sealing and insulating properties, and for example, a resin sealing material such as ionomer can be used.

[0082] Second rear surface-side sealing material 532 is a colored, non-transparent sealing material that does not substantially have light-transmitting properties, and is preferably a colored, opaque sealing material.

[0083] The second substrate 11 is an insulating substrate having sealing and insulating properties, and is a rear surface-side sealing substrate that constitutes the rear surface 151. The second substrate 11 is not particularly limited as long as it has sealing and insulating properties, and for example, a glass substrate such as float glass can be used.

[0084] In the above-described solar cell module 100, it is sometimes important to create a uniform design by evenly arranging the rectangular cells (solar cells 40) as a product feature. In this case, the key point is to control the spacing between the cells so that the components do not flow due to the flow and movement of the sealing material 105 during sealing, for example, lamination using a vacuum laminator. By using the sealing device 1 of this embodiment, such flow of the members is suppressed, making it possible to create a uniform design, and improving the design.

[0085] Furthermore, if such flow is suppressed by temporary fastening using tape, for example, not only is pressure concentrated at the corners of the laminated panel 2 during integration, but the pressure varies depending on the method of tape fastening. In other words, the flow state can vary depending on the worker's tape application method, which can result in a decrease in yield and an increase in labor hours, and in the first place, such flow cannot be completely prevented. In contrast, by using the sealing device 1 of the present invention, the load at the corners can be distributed and flow can be completely suppressed.

[0086] In the sealing device 1 of this embodiment, the edge pressing mechanism 30 is configured such that the edge pressing members 45, 46, 47, and 48 are pressed against each other by the retraction means 50, for example, by a fastener having a spring, thereby fixing the laminated panel 2 so that a force is applied inward from the periphery. This eliminates worker dependency when sealing the laminated panel 2, improves the inward pressing force of the laminated panel 2, suppresses outflow of the sealant, and ensures the fluidity of the sealant when sufficiently melted. This not only enables the quality of the laminated panel 2 to be uniform and ensures the long-term reliability of the laminated panel 2, but also improves the yield when integrating the sealant 15 and 16 with the first substrate 10 and the second substrate 11, reduces the number of steps required for tape application, and also reduces the number of steps required for removing portions of the sealant 15 and 16 that have leaked from the substrates 10 and 11.

[0087] In the above-described embodiments, each component can be freely substituted or added between the respective embodiments as long as it falls within the technical scope of the present invention. [Explanation of symbols]

[0088] 1: sealing device, 2: laminated panel, 5: first side, 6: second side, 7: third side, 8: fourth side, 10: first substrate, 11: second substrate, 15: front sealing material, 16: back sealing material, 30: Side pressing mechanism, 31: Melting and hardening mechanism, 45: First side pressing member, 46: second side pressing member, 47: third side pressing member, 48: fourth side pressing member 50: Retraction means, 55: First side pressing portion, 56: Second side pressing portion, 57: Third side pressing portion, 58: Fourth side pressing portion, 85: First end surface, 86: Second end surface, 87: Third end surface, 88: Fourth end surface, 105: Sealing material

Claims

1. A sealing device that melts and hardens a sealing material to seal a laminated panel having a sealing material sandwiched between a first substrate and a second substrate, The laminated panel has a first side and a second side when viewed in a plan view, A first edge pressing portion extending along the first edge and pressing a first end surface to which the first edge of the laminated panel belongs; A second edge pressing portion extending along the second edge and pressing a second end surface to which the second edge of the laminated panel belongs; Retraction means for retracting the first edge pressing portion and the second edge pressing portion toward the center of the laminated panel; a melting and hardening mechanism that hardens the sealing material when the first edge pressing portion contacts the first end surface and the second edge pressing portion contacts the second end surface by the retraction means.

2. The sealing device according to claim 1 , wherein the first side of the laminated panel faces the second side when viewed in a plan view.

3. The sealing device according to claim 1 or 2, wherein, as the retraction means retracts, the first edge pressing portion presses a majority of the first end surface, and the second edge pressing portion presses a majority of the second end surface.

4. a second retraction means for retracting the second-side pressing portion toward the first-side pressing portion, The sealing device according to claim 1 or 2, wherein the melting and hardening mechanism melts and hardens the sealing material in a state in which the first edge pressing portion is retracted toward the second edge pressing portion by the retraction means, and the second edge pressing portion is further retracted toward the first edge pressing portion by the second retraction means.

5. The laminated panel has a third side connecting the first side and the second side when viewed in a plan view, The retraction means has a third edge pressing portion that extends along the third edge and presses a third end surface to which the third edge of the laminated panel belongs, The sealing device according to claim 1 or 2, wherein the melting and hardening mechanism melts and hardens the sealing material in a state in which the first edge pressing portion presses the first end face, the second edge pressing portion presses the second end face, and the third edge pressing portion presses the third end face.

6. A plurality of edge pressing members are provided, Each side pressing member has a side pressing portion, The laminated panel has a polygonal shape when viewed in a plan view, The sealing device according to claim 1 or 2, wherein the edge pressing members retract so that the edge pressing portions of adjacent edge pressing members come into contact with the laminated panel.

7. a first side pressing member having the first side pressing portion, the melting and hardening mechanism has a sheet portion that covers the first substrate side, the melting and hardening mechanism presses the sheet portion from the outside of the first edge pressing member via the first edge pressing member so as to straddle the first substrate of the laminated panel in a plan view, thereby heating, melting, and hardening the sealing material; The sealing device according to claim 1 or 2, wherein the first-side pressing member has a rounded corner on the sheet portion side and opposite to the laminated panel.

8. A sealing device that melts and hardens the sealing material of a laminated panel in which a first substrate, a sheet-like sealing material, and a second substrate are laminated in this order, and seals the sealing material, The laminated panel is arranged so that the main surface of the first substrate and the main surfaces of the second substrates are the same shape, and each end surface of the first substrate and each end surface of the second substrate are flat, The sealing device melts and hardens the sealing material by a melting and hardening mechanism while pressing the flat surface by a pressing mechanism that presses the flat surface over the entire periphery.

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