U.S. patent application number 13/758480 was filed with the patent office on 2013-05-23 for coating nozzle, coating method, and inner volume control valve.
This patent application is currently assigned to NORDSON CORPORATION. The applicant listed for this patent is NORDSON CORPORATION. Invention is credited to Ryuichiro Shibata, Yoshinori Suzuki.
Application Number | 20130129915 13/758480 |
Document ID | / |
Family ID | 43536348 |
Filed Date | 2013-05-23 |
United States Patent
Application |
20130129915 |
Kind Code |
A1 |
Shibata; Ryuichiro ; et
al. |
May 23, 2013 |
COATING NOZZLE, COATING METHOD, AND INNER VOLUME CONTROL VALVE
Abstract
A coating nozzle includes a nozzle body including an inlet
opening for receiving a liquid supplied from a liquid supply valve
and an outlet opening, a distribution plate disposed adjacent to
the nozzle body and including an elongated bore in fluid
communication with the outlet opening, a shim plate disposed
adjacent to the distribution plate and including a shim plate
cutout communicating with the elongated bore of the distribution
plate, and a baffle plate disposed adjacent to the shim plate. At
least a portion of the shim plate cutout is located between the
first elongated bore and the baffle plate so as to define a
multi-face dispensing slot for dispensing the liquid onto at least
two faces of the substrate.
Inventors: |
Shibata; Ryuichiro; (Tokyo,
JP) ; Suzuki; Yoshinori; (Tokyo, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
NORDSON CORPORATION; |
Westlake |
OH |
US |
|
|
Assignee: |
NORDSON CORPORATION
Westlake
OH
|
Family ID: |
43536348 |
Appl. No.: |
13/758480 |
Filed: |
February 4, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
12844138 |
Jul 27, 2010 |
8387554 |
|
|
13758480 |
|
|
|
|
Current U.S.
Class: |
427/74 ;
239/562 |
Current CPC
Class: |
Y02E 10/50 20130101;
B05C 9/04 20130101; B05B 1/3013 20130101; H01L 31/18 20130101; H02S
30/10 20141201; B05B 13/0426 20130101; B05C 5/0216 20130101; B05C
5/001 20130101 |
Class at
Publication: |
427/74 ;
239/562 |
International
Class: |
H01L 31/18 20060101
H01L031/18; B05B 1/30 20060101 B05B001/30 |
Foreign Application Data
Date |
Code |
Application Number |
Aug 6, 2009 |
JP |
2009-183451 |
Claims
1. A coating method for dispensing liquid on a substrate including
an end face and at least two additional faces adjacent to the end
face with a nozzle including a nozzle body with a nozzle body
cutout, an inlet opening, and a first outlet opening in fluid
communication with a first elongate bore in a distribution plate
and a multi-face dispensing slot defined by a shim plate, the
method comprising: positioning the substrate within the nozzle body
cutout such that the dispensing slot is adjacent to the end face
and the at least two additional faces of the substrate; translating
the nozzle body in a first direction along the end face of the
substrate; delivering the liquid through the nozzle body from the
inlet opening to the first elongate bore via the first outlet
opening; and dispensing the liquid from the first elongate bore
through the multi-face dispensing slot such that at least the end
face of the substrate is coated with the liquid.
2. The coating method of claim 1, wherein the nozzle body further
includes a second outlet opening in fluid communication with a
second elongate bore in the distribution plate, and the method
further comprises: delivering the liquid through the nozzle body
from the inlet opening to the second elongate bore via the second
outlet opening; and dispensing the liquid from the second elongate
bore through the multi-face dispensing slot such that the end face
and at least one of the additional faces are simultaneously coated
with the liquid.
3. The coating method of claim 2, wherein the nozzle body further
includes an inner volume control valve including a cylinder in
fluid communication with the inlet opening and the first and second
outlet openings and a plunger operable to move in a reciprocating
manner in the cylinder, the method further comprising: moving the
plunger selectively between an extended position wherein liquid
flow through the second outlet opening is blocked such that liquid
is dispensed only on the end face of the substrate, and a retracted
position wherein liquid flow through the first and second outlet
openings is such that liquid is dispensed on the end face and at
least one of the additional faces of the substrate
simultaneously.
4. The coating method of claim 2, wherein the substrate includes
first, second, third, and fourth end faces adjacent to the two
additional faces, and the method further comprises: for the first
and third end faces: dispensing the liquid from the second elongate
bore through the multi-face dispensing slot to coat the end face
and the two additional faces as the nozzle body translates from a
first corner to a second corner, wherein the dispensed liquid
defines a predetermined width on the two additional faces; and for
the second and fourth end faces: dispensing the liquid from the
first elongate bore through the multi-face dispensing slot to coat
only the end face as the nozzle body translates from a first corner
to a first intermediate position which is the predetermined width
away from the first corner; then dispensing the liquid from the
second elongate bore through the multi-face dispensing slot to coat
the end face and the two additional faces as the nozzle body
translates from the first intermediate position to a second
intermediate position a predetermined width away from a second
corner; then dispensing the liquid from the first elongate bore
through the multi-face dispensing slot to coat only the end face as
the nozzle body translates from the second intermediate position to
the second corner.
5. The coating method of claim 1, wherein the substrate includes
first and second pairs of opposing end faces, and the method
further comprises: providing two of the nozzles spaced from one
another such that the respective nozzle body cutouts are directed
toward each other; aligning the first pair of opposing end faces
with the respective nozzle body cutouts; dispensing the liquid from
the first elongate bores through the multi-face dispensing slots as
the substrate translates in a first direction such that the first
pair of opposing end faces of the substrate is coated with the
liquid; rotating the substrate such that the second pair of
opposing end faces are aligned with the respective body cutouts;
and dispensing the liquid from the first elongate bores through the
multi-face dispensing slots as the substrate translates in a second
direction such that the second pair of opposing end faces of the
substrate is coated with the liquid.
6. The coating method of claim 1, wherein the substrate includes
first and second pairs of opposing end faces, and the method
further comprises: providing a first pair of the nozzles spaced
from one another such that the respective nozzle body cutouts are
directed toward each other along a first path; providing a second
pair of nozzles spaced from one another such that the respective
nozzle body cutouts are directed toward each other along a second
path generally orthogonal to the first path; dispensing the liquid
from the multi-face dispensing slots of the first pair of nozzles
as the substrate translates in a first direction along the first
path such that the first pair of opposing end faces of the
substrate is coated with the liquid; and dispensing the liquid from
the multi-face dispensing slots of the second pair of nozzles as
the substrate translates in a second direction along the second
path such that the second pair of opposing end faces of the
substrate is coated with the liquid.
7. An inner volume control valve configured for use in a nozzle
body having an inlet opening and a plurality of outlet openings,
the control valve comprising: a cylinder in fluid communication
with the inlet opening and each of the plurality of outlet
openings; a first plunger configured to move in a reciprocating
manner within the cylinder between a plurality of positions; a
first piston coupled to the first plunger; and at least one second
plunger and at least one second piston coupled to the first piston
and operable to control the movement of the first plunger between
the plurality of positions, wherein each of the plurality of
positions defines a first portion of the outlet openings which the
first plunger blocks during a dispensing operation from the inlet
opening to the remaining portion of the outlet openings.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of Ser. No. 12/844,138,
filed Jul. 27, 2010 (pending) which claims the priority of Japanese
Application No. 2009-183451 filed Aug. 6, 2009 (pending), the
disclosures of which are hereby incorporated by reference
herein.
TECHNICAL FIELD
[0002] The present invention relates to a coating nozzle and
coating method that can coat a liquid on a plurality of faces of a
substrate at one time, and to an inner volume control valve used in
the coating nozzle.
BACKGROUND
[0003] Conventionally, a solar cell panel is inserted into a
metallic outer frame with hot melt interposed as an adhesive or
seal material. A solar cell panel has, for example, transparent
electrodes provided at the rear side of a glass sheet of a
light-receiving face side. Amorphous silicon and thin-film
polycrystalline silicon are disposed between the transparent
electrodes and the rear-face electrodes. A groove-shaped engagement
portion for insertion of the solar cell panel is provided in the
metallic outer frame. According to the conventional method, hot
melt is coated at the engagement portion of the outer frame, and
subsequently the solar cell panel is inserted in the engagement
portion, thereby engaging the solar cell panel into the outer
frame.
[0004] However, holes and the like for installation are provided at
the engagement portion of the outer frame. In these circumstances,
applying hot melt, which is fluid, at the engagement portion of the
outer frame may not be desirable. Also, a large amount of hot melt
may be applied at the engagement portion in order to reliably
prevent water from entering between the solar cell panel and the
outer frame. In this case, excess hot melt overflows from the
engagement portion, and a step for removing the excess hot melt is
required.
[0005] In order to solve these problems related to application of
hot melt at the outer frame, a method has been proposed wherein hot
melt is applied to the solar cell panel. By applying hot melt on
the solar cell panel, it is possible to use fluid hot melt even
when assembling the solar cell panel and an outer frame that
includes holes for installation. Also, hot melt is applied directly
on the solar cell panel, so it is possible to more reliably prevent
water from entering the solar cell panel. Additionally a less
expensive outer frame may be used with the solar cell panel.
[0006] One example of a conventional apparatus and method is
provided at Japanese Patent Application No. 2000-243998.
[0007] In order to apply a liquid such as hot melt onto the outer
peripheral part of a substrate such as a solar cell panel using a
conventional coating device, three coating devices are typically
necessary to apply respective liquids onto the end face of the
substrate, the upper face of the substrate adjacent to the end
face, and the lower face of the substrate adjacent to the end face.
The three coating devices are respectively provided with a nozzle,
a liquid supply valve for supplying liquid to the nozzle, and a
liquid passage for supplying liquid to the liquid supply valve from
a liquid supply source. Thus, one problem is additional expense
incurred in providing a plurality of nozzles, a plurality of liquid
supply valves, and a plurality of liquid supply passages. Also, the
number of structural components increases, so a large space is
required for installing the plurality of coating nozzles.
[0008] In addition, a plurality of liquid supply passages is
necessarily provided from the liquid supply source to the plurality
of coating nozzles, which causes the piping for the plurality of
liquid supply passages to become complicated. Furthermore, the
operation of positioning the respective plurality of coating
nozzles with respect to the substrate takes time, and the operation
of adjusting the timing of starting and stopping dispensing by the
respective coating nozzles also takes time. In addition, the finish
of the seam between respective films formed by the plurality of
coating nozzles is not good. More specifically, the seam sticks
upward, or bulges out.
[0009] Therefore, the object of the present invention is to provide
a coating nozzle and coating method that can dispense liquid at the
end face of a substrate and at the faces of the substrate adjacent
to the end face. Also, the object of the present invention is to
provide an inner volume control valve used with the coating
nozzle.
SUMMARY OF THE INVENTION
[0010] In order to solve the problems described above, the present
invention is a coating nozzle including a nozzle body having an
inlet opening for receiving a liquid supplied from a liquid supply
valve and an outlet opening for dispensing the liquid. The coating
nozzle further includes a distribution plate, which is disposed
adjacent to the nozzle body, and having an elongated bore for
distributing the liquid dispensed from the outlet opening. The
coating nozzle also includes a shim plate, which is disposed
adjacent to the distribution plate, and provided with a cutout
communicating with the elongated bore of the distribution plate.
The coating nozzle further includes a baffle plate, which is
disposed adjacent to the shim plate, and covering the cutout of the
shim plate. A slot for dispensing the liquid on an end face of a
substrate and on faces of the substrate adjacent to the end face is
formed by the cutout of the shim plate between the distribution
plate and the baffle plate.
[0011] Also, the present invention was devised as a coating method
in order to solve the problems described above. More specifically,
the coating method includes applying the liquid on the end face of
the substrate and on faces of the substrate adjacent to the end
face while the coating nozzle is moved along an edge of the
substrate.
[0012] Also, the present invention includes an inner volume control
valve in order to solve the problems described above. More
specifically, the inner volume control valve includes a first entry
opening for receiving a liquid supplied from a liquid supply valve,
a plurality of exit openings for dispensing the liquid, and a
cylinder provided between the plurality of exit openings and the
first entry opening. The inner volume control valve also includes a
first plunger, moving reciprocatingly inside the cylinder, and
configured to stop at a plurality of positions inside the cylinder.
The inner volume control valve also includes a first piston coupled
to the first plunger, and one or more second plungers and second
pistons acting on the first piston in order to halt the first
plunger at the plurality of positions inside the cylinder. The
position at which the first plunger stops is selected from among
the plurality of positions in order to modify the number of exit
openings from which the liquid is dispensed.
[0013] The present invention provides a coating nozzle and coating
method that can dispense liquid at the end face of a substrate and
at the faces of the substrate adjacent to the end face. Also, the
present invention provides an inner volume control valve used with
the coating nozzle. The coating nozzle of the present invention can
dispense liquid at the end face of a substrate and at the faces of
the substrate adjacent to the end face, so it is possible to reduce
the expense of providing a plurality of nozzles, liquid supply
valves, and liquid supply passages. Furthermore, the coating nozzle
of the present invention can reduce the number of structural
components compared to a coating device that uses a plurality of
conventional coating nozzles, and can reduce the space for
installing the coating nozzle. In addition, the coating nozzle of
the present invention can reduce the number of liquid supply
passages from the liquid supply source to the coating nozzle
compared to a coating device that uses a plurality of conventional
coating nozzles. In this regard, the coating nozzle of the present
invention can reduce the time spent in attaching, positioning, and
adjusting coating nozzles, and the time spent in adjusting the
timing of starting and stopping dispensing. Moreover, the coating
nozzle of the present invention can perform coating without forming
seams between the coating film at the end face of the substrate and
the coating films at the faces of the substrate adjacent to the end
face.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a drawing showing a coating system in accordance
with the present invention.
[0015] FIG. 2 is an exploded perspective view of a three-face
coating nozzle of the coating system shown in FIG. 1.
[0016] FIG. 3 is a plan view of the three-face coating nozzle and
an inner volume control valve of the coating system shown in FIG.
1.
[0017] FIG. 4 is a cross-sectional view of the nozzle body of the
nozzle taken along line IV-IV in FIG. 3.
[0018] FIG. 5 is a front elevation view of the nozzle body of FIG.
4.
[0019] FIG. 6 is a side elevation view of the nozzle body of FIG.
4.
[0020] FIG. 7 is a perspective view of the nozzle body of FIG.
4.
[0021] FIG. 8 is an explanatory view drawn with the nozzle body of
FIG. 4 made transparent in order to show the hot melt passages of
the nozzle body.
[0022] FIG. 9 is a front elevation view of the distribution plate
of the coating system of FIG. 1.
[0023] FIG. 10 is a side elevation view of the distribution plate
of FIG. 9.
[0024] FIG. 11 is a front elevation view of the distribution plate
attached to the nozzle body of FIG. 4.
[0025] FIG. 12 is a side elevation view of the distribution plate
attached to the nozzle body of FIG. 4.
[0026] FIG. 13 is a perspective view of the distribution plate
attached to the nozzle body of FIG. 4.
[0027] FIG. 14 is a front elevation view of the shim plate of the
coating system of FIG. 1.
[0028] FIG. 15 is a side elevation view of the shim plate of FIG.
14.
[0029] FIG. 16 is a front elevation view of the shim plate attached
adjacent to the distribution plate of FIG. 9.
[0030] FIG. 17 is a side elevation view of the shim plate attached
adjacent to the distribution plate of FIG. 9.
[0031] FIG. 18 is a perspective view of the shim plate attached
adjacent to the distribution plate of FIG. 9.
[0032] FIG. 19 is a front elevation view of a baffle plate of the
coating system of FIG. 1.
[0033] FIG. 20 is a side elevation view of the baffle plate of FIG.
19.
[0034] FIG. 21 is an explanatory view of the nozzle tip of the
three-face coating nozzle of FIG. 2.
[0035] FIG. 22 is an enlarged view of the nozzle tip of FIG.
21.
[0036] FIG. 23 is a front elevation view of the baffle plate of
FIG. 19 attached adjacent to the shim plate of FIG. 14.
[0037] FIG. 24 is a side elevation view of the baffle plate
attached adjacent to the shim plate of FIG. 14.
[0038] FIG. 25 is a perspective view of the baffle plate attached
adjacent to the shim plate of FIG. 14.
[0039] FIG. 26 is a side elevation view of a first alternative
embodiment of the baffle plate of the coating system of FIG. 1.
[0040] FIG. 27 is a side elevation view of a second alternative
embodiment of the baffle plate of the coating system of FIG. 1.
[0041] FIG. 28 is a front elevation view of an attachment plate of
the coating system of FIG. 1.
[0042] FIG. 29 is a front elevation view of the attachment plate of
FIG. 28 attached adjacent to the baffle plate of FIG. 19.
[0043] FIG. 30 is a side elevation view of the attachment plate
attached adjacent to the baffle plate of FIG. 19.
[0044] FIG. 31 is a perspective view of the attachment plate
attached adjacent to the baffle plate of FIG. 19.
[0045] FIG. 32 is a view showing the three-face coating nozzle of
FIG. 2 fixed by screws to the attachment plate of FIG. 28.
[0046] FIG. 33 is a cross-section side elevation view of the
three-face coating nozzle taken partially along line
XXXIIIA-XXXIIIA in FIG. 32 and taken partially along line
XXXIIIB-XXXIIIB in FIG. 32.
[0047] FIG. 34 is a partially cut-away perspective view of the
three-face coating nozzle taken partially along line
XXXIIIA-XXXIIIA in FIG. 32 and taken partially along line
XXXIIIB-XXXIIIB in FIG. 32.
[0048] FIG. 35 is a view showing the inner volume control valve and
hot melt supply valve of the coating system of FIG. 1 between
dispensing cycles.
[0049] FIG. 36 is a view showing the inner volume control valve and
hot melt supply valve of FIG. 35 during a dispensing cycle.
[0050] FIG. 37 is a cross-section view of a hot melt coating film
coated on a solar cell panel using the three-face coating nozzle of
FIG. 2.
[0051] FIG. 38 is an explanatory view showing the hot melt coating
method.
[0052] FIG. 39 is an exploded perspective view of a three-face
coating nozzle according to a second embodiment of the coating
system.
[0053] FIG. 40 is a front elevation view of the dispersion plate
used with the second embodiment of the coating system.
[0054] FIG. 41 is a front elevation view of the dispersion plate of
FIG. 40 attached adjacent to a distribution plate.
[0055] FIG. 42 is a side elevation view of the dispersion plate
attached adjacent to the distribution plate of FIG. 41.
[0056] FIG. 43 is a perspective view of the dispersion plate
attached adjacent to the distribution plate of FIG. 41.
[0057] FIG. 44 is a front elevation view of a shim plate attached
adjacent to the dispersion plate of FIG. 40.
[0058] FIG. 45 is a side elevation view of the shim plate of FIG.
44 attached adjacent to the dispersion plate of FIG. 40.
[0059] FIG. 46 is a perspective view of the shim plate attached
adjacent to the dispersion plate of FIG. 40.
[0060] FIGS. 47(a)-(f) are collectively an explanatory view showing
the hot melt flow passage of the three-face coating nozzle of FIG.
39.
[0061] FIG. 48 is a front elevation view of a distribution plate
for the two-face coating nozzle according to a third embodiment of
the coating system.
[0062] FIG. 49 is a front elevation view of a shim plate for the
two-face coating nozzle of FIG. 48.
[0063] FIG. 50 is a view showing a solar cell panel coated with hot
melt.
[0064] FIG. 51 is an exploded view of the three-face coating nozzle
according to a fourth embodiment of the coating system.
[0065] FIG. 52 is a front elevation view of the nozzle body of the
nozzle of FIG. 51.
[0066] FIG. 53 is a side elevation view of the nozzle body of the
nozzle of FIG. 51.
[0067] FIG. 54 is a front elevation view of a distribution plate
used with the fourth embodiment of the coating system.
[0068] FIG. 55 is a front elevation view of a shim plate used with
the fourth embodiment of the coating system.
[0069] FIGS. 56(a)-56(c) are collectively an explanatory view
showing the operation of the inner volume control valve of the
nozzle of FIG. 51
[0070] FIGS. 57(a)-57(c) are collectively a view showing the
positional relationship between the first and second outlet
openings and the first plunger of the nozzle body of FIG. 52.
[0071] FIGS. 58(a)-58(c) are collectively an explanatory view
showing the operation of the first plunger and the hot melt supply
valve of the nozzle of FIG. 51.
[0072] FIG. 59 is a view showing the inner volume control valve and
hot melt supply valve of the nozzle of FIG. 51 between dispensing
cycles.
[0073] FIG. 60 is a view showing the inner volume control valve and
hot melt supply valve of the nozzle of FIG. 51 during a dispensing
cycle for applying liquid to three faces.
[0074] FIG. 61 is a view showing the inner volume control valve and
hot melt supply valve of the nozzle of FIG. 51 during a dispensing
cycle for applying liquid to one face.
[0075] FIG. 62 is an explanatory view showing a method of coating a
solar cell panel using a single coating device.
[0076] FIG. 63 is an explanatory view showing another method of
coating a solar cell panel using a single coating device.
[0077] FIG. 64 is an explanatory view showing yet another method of
coating a solar cell panel using a single coating device.
[0078] FIGS. 65(a)-65(c) are collectively an explanatory view
showing a method of coating a solar cell panel using two coating
devices.
[0079] FIG. 66 is an explanatory view showing a method of coating a
solar cell panel using four coating devices.
DETAILED DESCRIPTION
[0080] Preferred embodiments of the present invention will be
described below with reference to the accompanying drawings.
However, the dimensions, materials, shape, relative dispositions,
and so forth of the constituent components described in the
following embodiments do not limit the scope of the present
invention in any manner, unless specifically indicated
otherwise.
[0081] Coating System
[0082] FIG. 1 is a view showing a coating system in accordance with
a first embodiment of the present invention. In this embodiment, a
three-face coating device will be described as an example of a
multi-face coating device. A three-face coating device 1 is
attached to a robot arm 100. The robot arm 100 moves the three-face
coating device 1 along the edge of the object being coated (i.e., a
substrate), which is a solar cell panel 2 in FIG. 1. The solar cell
panel 2 is a panel used in electricity generation from sunlight.
The three-face coating device 1, while moving in the nozzle
movement directions indicated by arrows A1, A2, A3, and A4,
dispenses hot melt, which is a liquid such as an adhesive or
sealant, on the end face of the edge of the solar cell panel 2, on
the upper face (upper peripheral face) adjacent to the end face,
and on the lower face (rear peripheral face) adjacent to the end
face. This embodiment shows a configuration wherein the three-face
coating device 1 is moved with respect to the solar cell panel 2,
but the present invention is not limited to this operation. For
example, the solar cell panel 2 may be moved with respect to the
three-face coating device 1. Therefore, the nozzle movement
direction indicates the relative movement direction of the
three-face coating device 1 with respect to the solar cell panel
2.
[0083] The three-face coating device 1 includes a three-face
coating nozzle 10, an inner volume control valve 20, a hot melt
supply valve 30, and a gun 40. The three-face coating nozzle 10 has
a cutout 1 Or configured to receive the solar cell panel 2. In the
three-face coating nozzle 10, the cutout 1 Or for passage of the
solar cell panel 2 is formed in the shape of the letter U. The
inner volume control valve 20 is connected to a valve air control
circuit 60 via passages 51 and 52. Speed controllers 21 and 22 are
provided between the inner volume control valve 20 and the air
passages 51 and 52. The valve air control circuit 60 is connected
to an air supply source 70 via an air passage 53. The valve air
control circuit 60 is controlled by a first air control signal 111
from a control device 110. The gun 40 is connected to a hot melt
supply source 80 via a supply hot melt passage 54. The gun 40 is
also connected to a gun air control circuit 90 via an air passage
55. The gun air control circuit 90 is connected to the air supply
source 70 via an air passage 56. The gun air control circuit 90 is
controlled by a second air control signal 112 from the control
device 110.
[0084] Three-face Coating Nozzle
[0085] FIG. 2 is an exploded perspective view of the three-face
coating nozzle 10. The three-face coating nozzle 10 is attached to
one end of the inner volume control valve 20. The three-face
coating nozzle 10 comprises a nozzle body 11, a distribution plate
12, a shim plate 13, a baffle plate 14, and an attachment plate 15.
FIG. 3 is a plan view showing the three-face coating nozzle 10 and
the inner volume control valve 20.
[0086] FIG. 4 is a cross-sectional view of the nozzle body 11 taken
along line IV-IV in FIG. 3. The nozzle body 11 includes a cutout
11r for passage of the solar cell panel 2. The cutout 11r has a
width W1 and a length L1. The nozzle body 11 is attached to the hot
melt supply valve 30 by a nut 31. The nozzle body 11 is directly
attached to the hot melt supply valve 30, so the length of the hot
melt passage in this embodiment is short. If the length of the hot
melt passage were longer, a tapered coating film would be dispensed
at the start of the dispensing operation, and moreover, the
termination of the hot melt at the end of the dispensing operation
would not be desirable. In this embodiment, the occurrence of
tapered coating films at the start of the coating operation and
defective hot melt termination at the end of the coating operation
is reduced. An inlet opening 11a is provided in the nozzle body 11
to receive hot melt supplied from the hot melt supply valve 30. A
first hot melt passage 11b communicating with the inlet opening 11a
is provided in the nozzle body 11. Also, a cylinder 11c
intersecting and communicating with the first hot melt passage 11b
is provided in the nozzle body 11. The cylinder 11c is provided at
the side opposite the cutout 11r with respect to the first hot melt
passage 11b. A mounting bore 11d for mounting the inner volume
control valve 20 is provided in the nozzle body 11. The cylinder
11c opens to the mounting bore 11d. A plunger 23 of the inner
volume control valve 20 is inserted into the cylinder 11c. The
plunger 23 moves in a reciprocating manner inside the cylinder
11c.
[0087] FIG. 5 is a front elevation view of the nozzle body 11. An
outlet opening 11f for hot melt is provided in the attachment face
11e of the nozzle body 11, to which the distribution plate 12 is
attached. A temperature adjustment heater 17 and a temperature
sensor 18 are provided in the nozzle body 11. When the nozzle body
11 is cooled by ambient air and the solar cell panel 2, and the
temperature of the nozzle body 11 drops, the termination of hot
melt may not be desirable when the dispensing of hot melt ends.
Therefore, the temperature adjustment heater 17 is provided in the
nozzle body 11 in order to heat the nozzle body 11 and maintain an
appropriate temperature. The temperature sensor 18 detects the
temperature of the nozzle body 11. Based on the temperature
detected by the temperature sensor 18, the control device 110
controls the temperature adjustment heater 17 and holds the nozzle
body 11 at an appropriate temperature. As a result, termination of
hot melt when the dispensing of hot melt ends is desirable.
[0088] FIG. 6 is a side elevation view of the nozzle body 11. A
second hot melt passage 11g in the nozzle body 11 communicates with
the outlet opening 11f. In this embodiment, the second hot melt
passage 11g extends parallel to direction A, the direction of
relative movement of the three-face coating nozzle 10 with respect
to the solar cell panel 2. Also, the first hot melt passage 11b
extends perpendicularly with respect to the second hot melt passage
11g. The cylinder 11c communicates with the first hot melt passage
11b at a junction 11h of the first hot melt passage 11b and the
second hot melt passage 11g.
[0089] FIG. 7 is a perspective view of the nozzle body 11. FIG. 8
is an explanatory view drawn with the nozzle body 11 drawn
transparent in order to show the hot melt passages of the nozzle
body 11. When a hot melt supply valve 30 is attached to the nozzle
body 11 by the nut 31, hot melt is supplied to the inlet opening 11
a of the nozzle body 11. Hot melt flows from the inlet opening 11a,
through the first hot melt passage 11b, and to the junction 11h. At
this time, the tip of the plunger 23 inside the cylinder 11c is
near the junction 11h. Hot melt flows from the junction 11h,
through the second hot melt passage 11g, and to the outlet opening
11f.
[0090] Distribution Plate
[0091] FIG. 9 is a front elevation view of the distribution plate
12. The distribution plate 12 includes a cutout 12r for passage of
the solar cell panel 2. The cutout 12r has a width W2 and a length
L2. The top side of the cutout 12r and the intermediate side are
joined by an arc with radius R, and the lower side of the cutout
12r and the intermediate side are joined by an arc with radius R.
The width W2 of the cutout 12r of the distribution plate 12 is
equal to or smaller than the width W1 of the cutout 11r of the
nozzle body 11. Also, when the left end of the nozzle body 11 of
FIG. 4 and the left end of the distribution plate 12 of FIG. 9 are
disposed adjacent one another and attached, the length L2 of the
cutout 12r of the distribution plate 12 is equal to or smaller than
length L1 of the cutout 11r of the nozzle body 11. The dimensions
of the width W2, the length L2, and the radius R of the
distribution plate 12 can be selected to correspond to the desired
coating shape and coating film thickness.
[0092] A U-shaped elongated bore 12a is provided in the
distribution plate 12 along the periphery of the cutout 12r. The
elongated bore 12a, as shown in FIG. 9, includes the vertical
elongated bore 12a1; the upper lateral elongated bore 12a2, which
extends horizontally from one end of the vertical elongated bore
12a1 along the upper side of the cutout 12r; and the lower lateral
elongated bore 12a3, which extends horizontally from the other end
of the vertical elongated bore 12a1 along the lower side of the
cutout 12r. The elongated bore 12a has a width W3. The width W3
dimension affects the flow of hot melt and the uniformity of its
distribution. A distance D1 defined between the cutout 12r and the
elongated bore 12a determines the flow passage length of the slot
that dispenses hot melt. Six holes 12b for receiving attachment
screws are provided in the distribution plate 12.
[0093] FIG. 10 is a side elevation view of the distribution plate
12. The distribution plate 12 has a thickness T1. The thickness T1
of the distribution plate 12 determines the volume of the hot melt
reservoir inside the three-face coating nozzle 10. Below, the flow
of hot melt in the distribution plate 12 will be described.
[0094] FIG. 11, FIG. 12, and FIG. 13 are, respectively, a front
elevation view, a side elevation view, and a perspective view of
the distribution plate 12 attached to the nozzle body 11. Hot melt
supplied from the hot melt supply valve 30 flows from the inlet
opening 11a of the nozzle body 11, passes through the first hot
melt passage 11b, junction 11h, and second hot melt passage 11g,
then flows to the outlet opening 11f, and is dispensed from the
outlet opening 11f. Hot melt dispensed from the outlet opening 11f
flows and is distributed to the top and bottom of the vertical
elongated bore 12a1 of the distribution plate 12. Hot melt that
flows to the top flows inside the upper lateral elongated bore 12a2
and fills the interior of the upper lateral elongated bore 12a2.
Hot melt that flows to the bottom flows inside the lower lateral
elongated bore 12a3 and fills the interior of the lower lateral
elongated bore 12a3.
[0095] Hot melt is distributed by the distribution plate 12 to the
dispensing port corresponding to the end face of the solar cell
panel 2, the dispensing port corresponding to the upper face, and
the dispensing port corresponding to the lower face. The vertical
elongated bore 12a1, upper lateral elongated bore 12a2, and lower
lateral elongated bore 12a3 of the distribution plate 12 form a hot
melt reservoir.
[0096] Shim Plate
[0097] FIG. 14 is a front elevation view of the shim plate 13. The
shim plate 13 includes a first cutout 13r for passage of the solar
cell panel 2. The first cutout 13r has a width W2 and a length L3.
The width W2 of the first cutout 13r is equal to the width W2 of
the cutout 12r of the distribution plate 12. The length L3 of the
first cutout 13r is equal to the distance D2 from the left end 12c
of the distribution plate 12 shown in FIG. 9 to the ends of the
upper lateral elongated bore 12a2 and lower lateral elongated bore
12a3. However, the width W2 and the length L3 are not limited to
this in other embodiments.
[0098] A second cutout 13a is provided in the shim plate 13. The
second cutout 13a communicates with the first cutout 13r. The
second cutout 13a has a width W4 and a length L4. The width W4 of
the second cutout 13a is equal to the length of the vertical
elongated bore 12a1 of the distribution plate 12. The length L4 of
the second cutout 13a is equal to the length of the upper lateral
elongated bore 12a2 or lower lateral elongated bore 12a3. However,
the width W4 and the length L4 are not limited to this in other
embodiments.
[0099] When the shim plate 13 is disposed adjacent to the
distribution plate 12, the second cutout 13a of the shim plate 13
communicates with the vertical elongated bore 12a1, the upper
lateral elongated bore 12a2, and the lower lateral elongated bore
12a3 of the distribution plate 12. In this embodiment, the second
cutout 13a of the shim plate 13 has dimensions which exactly
surround the vertical elongated bore 12a1, the upper lateral
elongated bore 12a2, and the lower lateral elongated bore 12a3 of
the distribution plate 12. However, the dimensions of the second
cutout 13a may not be limited to this. The second cutout 13a of the
shim plate 13 defines a plurality of slots for dispensing hot melt
to the solar cell panel 2. In this embodiment, the plurality of
slots is continuously formed. The width W2 and the length L3 of the
first cutout 13r and the width W4 and the length L4 of the second
cutout 13a can be selected to correspond to the desired coating
shape and coating film thickness.
[0100] Six holes 13b for receiving attachment screws are provided
in the shim plate 13. FIG. 15 is a side elevation view of the shim
plate 13. The shim plate 13 has a thickness T2. The thickness T2 of
the shim plate 13 determines the width of the slot that dispenses
hot melt.
[0101] FIG. 16, FIG. 17, and FIG. 18 are, respectively, a front
elevation view, a side elevation view, and a perspective view of
the shim plate 13 attached adjacent to the distribution plate 12.
Hot melt flows from the vertical elongated bore 12a1, the upper
lateral elongated bore 12a2, and the lower lateral elongated bore
12a3 of the distribution plate 12 to slots 13a1, 13a2, and 13a3
respectively.
[0102] Baffle Plate
[0103] FIG. 19 is a front elevation view of the baffle plate 14.
FIG. 20 is a side elevation view of the baffle plate 14. The baffle
plate 14 includes a cutout 14r for receiving the solar cell panel
2. The cutout 14r has a width W2 and a length L2. The top side of
the cutout 14r and the intermediate side are joined by an arc with
radius R, and the lower side of the cutout 14r and the intermediate
side are joined by an arc with radius R. In this embodiment, the
width W2 of the cutout 14r of the baffle plate 14 is equal to the
width W2 of the cutout 12r of the distribution plate 12. Also, the
length L2 of the cutout 14r of the baffle plate 14 is equal to the
length L2 of the cutout 12r of the distribution plate 12. However,
the width W2 and the length L2 of the cutout 14r are not limited to
this. The dimensions of the width W2, the length L2, and radius R
of the baffle plate 14 can be selected to correspond to the desired
coating shape and coating film thickness. Six holes 14b for
receiving attachment screws are provided in the baffle plate
14.
[0104] FIG. 20 is a side elevation view of the baffle plate 14. The
baffle plate 14 has a thickness T3. The thickness T3 of the baffle
plate 14 determines the length of the lip of the nozzle. The cutout
14r includes parallel part 14r1 and inclined part 14r2. The
parallel part 14r1 is parallel to nozzle movement direction A. The
inclined part 14r2 is inclined with respect to nozzle movement
direction A, and widens toward the downstream side of nozzle
movement direction A. The shape of the cutout 14r affects coating
uniformity, the appearance of the coating film, and termination
quality. The shape of the cutout 14r is selected to correspond to
the coating speed and type of adhesive so as to produce the best
coating.
[0105] Next, the effect of the shape of the cutout 14r on coating
termination quality will be explained. FIG. 21 is an explanatory
view of the nozzle tip of the three-face coating nozzle 10. The
three-faced coating nozzle 10 is moved by the robot arm 100, with
respect to the solar cell panel 2, in the nozzle movement direction
A. Hot melt dispensed from the outlet opening 11f of the nozzle
body 11 passes through the vertical elongated bore 12a1 of the
distribution plate 12, and flows to the slot 13a1. The slot 13a1 is
formed by the second cutout 13a of the shim plate 13 between the
distribution plate 12 and the baffle plate 14. Hot melt dispensed
from the slot 13a1 forms a coating film 3 on an end face 2e of the
solar cell panel 2.
[0106] FIG. 22 is an enlarged view of the nozzle tip. The parallel
part 14r1 of the baffle plate 14 defines a plane, having length L5,
parallel to nozzle movement direction A. The inclined part 14r2 is
continuous with the parallel part 14r1 and is located at the
downstream side of nozzle movement direction A from the parallel
part 14r1. The inclined part 14r2 of the baffle plate 14 is
chamfered so as to define an inclined face having an inclination of
angle 0 with respect to the parallel part 14r1. The inclined part
14r2 is inclined in the direction away from the solar cell panel 2.
Hot melt dispensed from the slot 13a1 is smoothed by the parallel
part 14r1, and made uniform. At contact line 14p between the
parallel part 14r1 and the inclined part 14r2, the cutout 14r of
the baffle plate 14 creates a separation of the dispensed hot melt,
at least in theory. Nevertheless, dispensed hot melt may wrap
around the inclined face 14r2. This wrapped hot melt 3a is the
cause of stringing.
[0107] The shape of the cutout 14r of the baffle plate 14 affects
the cut-off of the dispensed hot melt. The shorter that the length
L5 of the horizontal part 14r1 of the cutout 14r becomes, the less
the contact between the horizontal part 14r1 and the hot melt.
Therefore, the amount of hot melt that wraps around and adheres to
the inclined face 14r2 is minimized, and the termination is
desirable. However, a suitable length for the length L5 is selected
according to the viscosity of the hot melt, coating speed, and
coating amount. The inclined part 14r2 also minimizes the amount of
remaining hot melt which wraps around, thereby minimizing
stringing. An appropriate value is selected for the angle .theta.
of the inclined part 14r2, according to the viscosity of the hot
melt, coating speed, and coating amount.
[0108] FIG. 23, FIG. 24, and FIG. 25 are, respectively, a front
elevation view, a side elevation view, and a perspective view of
the baffle plate 14 attached adjacent to the shim plate 13. The
baffle plate 14 is attached so as to cover the second cutout 13a of
the shim plate 13. The second cutout 13a of the shim plate 13,
located between the distribution plate 12 and the baffle plate 14,
forms the first slot 13a1 for dispensing hot melt on the end face
2e of the solar cell panel 2, the second slot 13a2 for dispensing
hot melt on the upper face, and third slot 13a3 for dispensing hot
melt on the lower face. The first slot 13a1 and the second slot
13a2 are continuous. Also, the first slot 13a1 and the third slot
13a3 are continuous. Therefore, the upper face 2t, end face 2e, and
lower face 2b of the end of the solar cell panel 2 can be
continuously coated.
[0109] Next, alternative embodiments of the baffle plate 14 will be
illustrated. FIG. 26 is a side elevation view of a first
alternative embodiment of a baffle plate 114. A cutout part 114r of
the baffle plate 114 is formed as a face having an arc-shaped
cross-section. The shape opens to the upstream side in the nozzle
movement direction A. FIG. 27 is a side elevation view of a second
alternative embodiment of for a baffle plate 214. A cutout part
214r of the baffle plate 214 comprises a parallel part 214r1
parallel to nozzle movement direction A, an inclined part 214r2
having an angle with respect to nozzle movement direction A, and a
recess-shaped depression 214r3 connecting the parallel part 214r1
and the inclined part 214r2. The inclined part 214r2 widens toward
the downstream side of nozzle movement direction A. The shape of
the cutout of the baffle plate affects the cut-off of dispensed hot
melt, so an appropriate shape is selected according to the
viscosity of the hot melt, coating speed, and coating amount.
Furthermore, in these embodiments a baffle plate is used, but the
present invention does not necessarily have to use a baffle plate.
For example, it is possible to omit the baffle plate and attach the
attachment plate described below adjacent to the shim plate.
[0110] Attachment Plate
[0111] FIG. 28 is a front elevation view of the attachment plate
15. The attachment plate 15 includes a cutout 15r for receiving the
solar cell panel 2. The cutout 15r has a width W5 and a length L6.
The width W5 is equal to or longer than twice the width of the
inclined part 14r2 added to the width W2 of the cutout 14r of the
baffle plate 14. The length L6 is equal to or longer than the width
of the inclined part 14r2 added to the length L2 of the cutout 14r
of the baffle plate 14. Six countersunk holes 15b for accommodating
the heads of screws 4 are provided in the attachment plate 15.
[0112] FIG. 29, FIG. 30, and FIG. 31 are, respectively, a front
elevation view, a side elevation view, and a perspective view of
the attachment plate 15 attached adjacent to the baffle plate 14.
The distribution plate 12, the shim plate 13, and the baffle plate
14, which collectively form the first, second, and third slots
13a1, 13a2, and 13a3, each extend into the cutout more than the
nozzle body 11 or attachment plate 15.
[0113] Hot Melt Flow Passage
[0114] FIG. 32 is a view showing the three-face coating nozzle 10
fixed by screws 4. The distribution plate 12, the shim plate 13,
the baffle plate 14, and the attachment plate 15 are attached to
the nozzle body 10 by six screws 4. FIG. 33 and FIG. 34 are,
respectively, a cross-section side elevation view and a
cross-section perspective view of the three-face coating nozzle 10
taken partially along line XXXIIIA-XXXIIIA and taken partially
along line XXXIIIB-XXXIIIB in FIG. 32. The screws 4 are omitted in
this figure.
[0115] Hot melt is supplied from the hot melt supply valve 30,
attached to the nozzle body 11 by the nut 31, to the inlet opening
11a of the nozzle body 11. Hot melt passes through the first hot
melt passage 11b and reaches the junction 11h of the first and
second hot melt passages 11 b and 11g. Hot melt passes from the
junction 11h to the second hot melt passage 11g, and is dispensed
from the outlet opening 11f to the vertical elongated bore 12a1 of
the distribution plate 12. Hot melt flows from the vertical
elongated bore 12a1 to the upper lateral elongated bore 12a2 and
the lower lateral elongated bore 12a3. Hot melt passes from the
vertical elongated bore 12a1, the upper lateral elongated bore
12a2, and the lower lateral elongated bore 12a3 through the second
cutout 13a of the shim plate 13, and is dispensed from the first,
second, and third slots 13a1, 13a2, and 13a3 formed between the
distribution plate 12 and the baffle plate 14.
[0116] Operation Between Dispensing Cycles
[0117] Below, the operation of the three-face coating device 1 will
be described. FIG. 35 is a view showing the inner volume control
valve 20 and the hot melt supply valve 30 before and after
dispensing hot melt. The inner volume control valve 20 is fixed to
the nozzle body 11 by a tightening member such as a screw (not
shown in the drawings). The plunger 23 is provided in the inner
volume control valve 20 so that it can move in a reciprocating
manner. One end of the plunger 23 is inserted into the cylinder 11c
of the nozzle body 11. The other end of the plunger 23 is fixed to
a piston 24. The piston 24 is provided so that it can move in a
reciprocating manner inside a piston chamber 25 of the inner volume
control valve 20. The piston 24 divides the piston chamber 25 into
a first chamber 25a and a second chamber 25b.
[0118] The air supply source 70 supplies air to the valve air
control circuit 60 via the air passage 53. Before and after
dispensing hot melt, the valve air control circuit 60 supplies air
to the first chamber 25a of the piston chamber 25 via the air
passage 52 and the speed controller 22. Meanwhile, air in the
second chamber 25b of the piston chamber 25 is sent to the valve
air control circuit 60 via the speed controller 21 and the air
passage 51, and is discharged from the valve air control circuit 60
to the atmosphere. The pressure inside the first chamber 25a is
higher than the pressure inside the second chamber 25b, so the
piston 24 moves to shrink the second chamber 25b and expand the
first chamber 25a. Because of the movement of the piston 24, the
tip of the plunger 23 moves in the direction of increasing distance
from the junction 11h of the nozzle body 11, to a retracted
position inside the cylinder 11c. When this movement occurs, the
plunger 23 sucks the hot melt that is inside the second hot melt
passage 11g through the junction 11h and to the cylinder 11c. This
is usually called a suck-back function. The suck-back function
increases the volume of the hot melt passage inside the nozzle body
11, thereby improving termination when hot melt dispensing
stops.
[0119] Furthermore, the speed controllers 21 and 22, operating as
aperture valves, control the movement speed of the piston 24 by
adjusting the flow of air.
[0120] The hot melt supply valve 30 is fixed to the nozzle body 11
by the nut 31. A hot melt chamber 32 is provided in the hot melt
supply valve 30. The hot melt chamber 32 communicates with an inlet
port 33 where hot melt flows in, and with a dispensing port 34 for
dispensing hot melt. The gun 40 is fixed to the hot melt supply
valve 30. The gun 40 includes a gun hot melt passage 41. One end of
the gun hot melt passage 41 communicates with the inlet port 33 of
the hot melt supply valve 30, and the other end of the gun hot melt
passage 41 communicates with the supply hot melt passage 54
connected to the hot melt supply source 80. Hot melt from the hot
melt supply source 80 passes through the supply hot melt passage
54, the gun hot melt passage 41 of the gun 40, and the inlet port
33 and is then supplied to the hot melt chamber 32. The hot melt
supply valve 30 includes a valve rod 35 that moves in a
reciprocating manner inside the hot melt chamber 32. One end of the
valve rod 35 touches and separates from a valve seat 36 provided
near the discharge port 34. The other end of the valve rod 35 is
fixed to a piston 37. The piston 37 divides a piston chamber 38
into a first chamber 38a and a second chamber 38b. The first
chamber 38a communicates with one end of the air passage 42 of the
gun 40. The other end of the air passage 42 communicates with the
air passage 55 connected to the gun air control circuit 90. Before
and after dispensing hot melt, the gun air control circuit 90
releases the first chamber 38a of the piston chamber 38 to the
atmosphere via the air passage 55 and the air passage 42 of the gun
40. The second chamber 38b of the piston chamber 38 is provided
with a spring 39 for energizing the piston 37. The piston 37 is
pushed by the energizing force of the spring 39, touches one end of
the valve rod 35 to the valve seat 36, and closes the dispensing
port 34. Therefore, dispensing of hot melt inside the hot melt
chamber 32 from the dispensing port 34 is prevented.
[0121] Operation During Dispensing
[0122] FIG. 36 is a view showing the inner volume control valve 20
and the hot melt supply valve 30 during hot melt dispensing. When
dispensing hot melt, the control device 110 controls the valve air
control circuit 60 using the first air control signal 111, and
supplies air from the air supply source 70 to the air passage 51.
Air is supplied to the second chamber 25b of the piston chamber 25
via the air passage 51 and the spin controller 21. Meanwhile, the
second chamber 25b expands and the first chamber 25a shrinks as the
piston 24 moves. Because of this movement of the piston 24, the tip
of the plunger 23 extends and moves to a position near the junction
11h. As a result, the volume inside the cylinder 11c becomes
small.
[0123] The control device 110 controls the gun air control circuit
90 using the second air control signal 112, and air from the air
supply source 70 is supplied to the air passage 42. Air is supplied
to the first chamber 38a of the piston chamber 38, and expands the
first chamber 38a by moving the piston 37 against the energizing
force of the spring 39 in the second chamber 38b. Because of
movement of the piston 37, the valve rod 35 separates from the
valve seat 36 and opens the dispensing port 34. Hot melt in the hot
melt chamber 32 is dispensed from the dispensing port 34 to the
inlet opening 11a of the nozzle body 11. Hot melt passes from the
outlet opening 11f of the nozzle body 11 through the vertical
elongated bore 12a1, the upper lateral elongated bore 12a2, and the
lower lateral elongated bore 12a3 of the distribution plate 12, and
is then dispensed from the first slot 13a1, the second slot 13a2,
and the third slot 13a3.
[0124] Coating Method
[0125] FIG. 37 is a cross-section view of a hot melt coating film 3
coated on a solar cell panel 2 using the three-face coating nozzle
10 of Embodiment 1. It is also a cross-sectional view taken along
line XXXVII-XXXVII in FIG. 38. In the three-face coating nozzle 10,
the cross-section of the portion where the slot is formed is
U-shaped. Hot melt dispensed from the first slot 13a1 of the
three-face coating nozzle 10 is dispensed on the end face 2e of the
solar cell panel 2. In the same way, hot melt dispensed from the
second slot 13a2 is dispensed on the upper face 2t of the end of
the solar cell panel 2. And hot melt dispensed from the third slot
13a3 is dispensed on the lower face 2b of the end of the solar cell
panel 2. The first, second, and third slots 13a1, 13a2, and 13a3
are continuous, so the coating film 3 dispensed on the upper face
2t, end face 2e, and lower face 2b of the end of the solar cell
panel 2 is continuous. Therefore, the coating film 3 is a coating
film formed without seams.
[0126] FIG. 38 is an explanatory view showing the hot melt coating
method. The solar cell panel 2 is transported to a predetermined
position by a transport device such as a belt conveyor (not shown
in the drawings), and fixed at the predetermined position by a
fixing device (not shown in the drawings). The four edges of the
solar cell panel 2 are coated with hot melt by the three-face
coating nozzle 10. The three-face coating nozzle 10 coats hot melt
while being moved in nozzle movement direction A. Hot melt, as
shown in FIG. 37, is dispensed from the first, second, and third
slots 13a1, 13a2, and 13a3 and is dispensed on the upper face 2t,
end face 2e, and lower face 2b of the end of the solar cell panel
2. When coating a corner 2c of the solar cell panel 2, there are
two coating methods. In the first coating method, the three-face
coating nozzle 10 moves in nozzle movement direction Al and
temporarily overshoots the corner 2c. When this occurs, dispensing
hot melt is temporarily halted. Next, the three-face coating nozzle
10 is rotated 90.degree.. The three-face coating nozzle is moved in
nozzle movement direction A2, and dispensing hot melt is restarted
at the corner 2c of the solar cell panel 2. In the second coating
method, while the three-face coating nozzle 10 is coating hot melt
at the corner 2c it is rotated 90.degree. to the left, as indicated
by arrow B, without separating from the panel 2.
[0127] The four edges of the solar cell panel 2 are coated with hot
melt by repeating the coating methods. When dispensing ends, the
panel 2 is transported by the transport device. In the case of
continuous coating, the next panel 2 is transported to the
predetermined position by the transport device and fixed by the
fixing device. By repeating the same sort of operation, hot melt is
coated on the four edges of a plurality of panels 2 continuously.
According to this embodiment, U-shaped coating (three-face coating)
can be performed in a single step on one edge of a panel, so this
operation speeds up a production line and increases the amount of
production.
[0128] Dimension Changes
[0129] With a conventional nozzle, when the coating width of the
hot melt or the dimensions of the substrate change it is necessary
to remake the nozzle itself. In contrast, the coating nozzle 10 of
this embodiment can handle changing dispensing widths of the hot
melt or changing dimensions of the substrate simply by changing the
dimensions of the distribution plate and shim plate. Thus, the
nozzle 10 can handle a wider range of dimensions than a
conventional nozzle, without remaking the nozzle body. More
specifically, a single coating nozzle can be applied to dispensing
hot melt on many types of substrates, which is economically
advantageous.
[0130] The coating nozzle of this embodiment is not limited to a U
shape; complicated curved-surface shapes may also be used in other
embodiments. As described above, the coating nozzle 10 of this
embodiment can dispense a liquid on the end face of a substrate and
on the faces of the substrate adjacent to the end face, so it is
possible to reduce the expense of providing a plurality of nozzles,
a plurality of liquid supply valves, and a plurality of liquid
supply passages. Also, the coating nozzle of this embodiment can
reduce the number of structural components compared to a coating
device that uses a plurality of conventional coating nozzles, and
can reduce the space for installing the coating device.
Furthermore, the coating nozzle of this embodiment can reduce the
number of liquid supply passages from the liquid supply source to
the coating device compared to a coating device that uses a
plurality of conventional coating nozzles.
[0131] Moreover, the coating nozzle of this embodiment can reduce
the time spent in attaching, positioning, and adjusting coating
nozzles, and the time spent in adjusting the timing of starting
stopping dispensing compared to a coating device that uses a
plurality of conventional coating nozzles. Additionally, the
coating nozzle of this embodiment can perform coating without
forming seams between the coating film at the end face of the
substrate and the coating films at the faces of the substrate
adjacent to the end face. Therefore, it is possible to create a
coating with a desirable appearance. In addition, the coating
nozzle of this embodiment uses an inner volume control valve, so it
can create a desirable termination or "cut-off" when dispensing
ends. Also, stringing of hot melt after coating ends can be
reduced. Furthermore, the coating nozzle of this embodiment
includes a temperature adjustment heater and a temperature sensor,
so it can perform dispensing consistent with the characteristics of
a wide range of materials and ranging from low temperature to high
temperature.
[0132] FIG. 39 is an exploded perspective view of a three-face
coating nozzle 210 according to a second embodiment of the
invention. In the three-face coating nozzle 10 shown in FIG. 2, the
shim plate 13 was attached adjacent to the distribution plate 12.
In this embodiment a dispersion plate 16 is provided between the
distribution plate 12 and the shim plate 13. The three-face coating
nozzle 210 of this embodiment has the same elements as the
three-face coating nozzle 10 of the first embodiment, except for
the dispersion plate 16. Consequently, the same reference numbers
are applied to the same elements, and explanation thereof is
largely omitted.
[0133] Dispersion Plate
[0134] FIG. 40 is a front elevation view of the dispersion plate
16. The dispersion plate 16 includes a cutout 16r for passage of
the solar cell panel 2. The cutout 16r has a width W2 and a length
L2. The top side of the cutout 16r and the intermediate side are
joined by an arc with radius R, and the lower side of the cutout
16r and the intermediate side are joined by an arc with radius R.
The width W2, the length L2, and radius R of the cutout 16r are
equal to width W2, length L2, and radius R of the distribution
plate 12.
[0135] A plurality of through bores 16a are provided in the
dispersion plate 16 at portions corresponding to the vertical
elongated bore 12a1, the upper lateral elongated bore 12a2, and the
lower lateral elongated bore 12a3 of the distribution plate 12. In
this embodiment, eight through bores 16a are provided. The
plurality of through bores 16a in the dispersion plate 16 improve
the dispersion of hot melt flowing from the vertical elongated bore
12a1, the upper lateral elongated bore 126a2, and the lower lateral
elongated bore 12a3 of the distribution plate 12 to the second
cutout 13a of the shim plate 13. As a result, the dispersion plate
16 promotes uniform flow of hot melt from the distribution plate 12
to the shim plate 13. Six holes 16b for receiving attachment screws
4 are provided in the dispersion plate 16.
[0136] FIG. 41, FIG. 42, and FIG. 43 are, respectively, a front
elevation view, a side elevation view, and a perspective view of
the dispersion plate 16 attached adjacent to the distribution plate
12. Hot melt dispensed from the outlet opening 11f of the nozzle
body 11 flows to the upper lateral elongated bore 12a2 and the
lower lateral elongated bore 12a3 via the vertical elongated bore
12a1 of the distribution plate 12. Because of the dispersion plate
16, hot melt can sufficiently flow to the ends of the upper lateral
elongated bore 12a2 and lower lateral elongated bore 12a3.
[0137] FIG. 44, FIG. 45, and FIG. 46 are, respectively, a front
elevation view, a side elevation view, and a perspective view of
the shim plate 13 attached adjacent to the dispersion plate 16. Hot
melt flows from the eight through bores 16a provided in the
dispersion plate 16 to the second cutout 13a of the shim plate 13.
As a result, hot melt flowing in the first, second, and third slots
13a1, 13a2, and 13a3 formed by the second cutout 13a of the shim
plate 13 is made uniform.
[0138] Hot Melt Flow Passage
[0139] FIGS. 47(a)-47(f) are collectively an explanatory view
showing the hot melt flow passage of the three-face coating nozzle
210 of the second embodiment. FIG. 47(a) is a view showing the hot
melt flow passage of the nozzle body 11. Hot melt flows from the
inlet opening 11a, through the first hot melt passage 11b, to the
junction 11h. At this time, the tip of the plunger 23 of the inner
volume control valve 20 is near the junction 11h. Hot melt flows
from the junction 11h, through the second hot melt passage 11g, and
to the outlet opening 11f. FIG. 47(b) is a view showing the hot
melt flow passage of the distribution plate 12. Hot melt from the
exit opening 11f is dispensed to the vertical elongated bore 12a1
of the distribution plate 12. Hot melt is distributed to the top
and bottom of the vertical elongated bore 12a1. Hot melt
distributed to the top flows inside the upper lateral elongated
bore 12a2 and fills the upper lateral elongated bore 12a2. Hot melt
distributed to the bottom flows inside the lower lateral elongated
bore 12a3 and fills the lower lateral elongated bore 12a3.
[0140] FIG. 47(c) shows the hot melt flow passage of the dispersion
plate 16. Because of the dispersion plate 16, hot melt can
sufficiently flow to the ends of the upper lateral elongated bore
12a2 and the lower lateral elongated bore 12a3. Hot melt flows from
the vertical elongated bore 12a1, the upper lateral elongated bore
12a2, and the lower lateral elongated bore 12a3, through the
plurality of through bores 16a of the dispersion plate 16, to the
second cutout 13a of the shim plate 13. FIG. 47(d) shows the hot
melt flow passage of the shim plate 13. Hot melt dispensed from the
plurality of through bores 16a of the dispersion plate 16 uniformly
spreads inside the second cutout 13a of the shim plate 13. FIG.
47(e) shows the operational state when the second cutout 13a of the
shim plate 13 is covered by the baffle plate 14. Hot melt is
dispensed from the first, second, and third slots 13a1, 13a2, and
13a3 formed by the second cutout 13a of the shim plate 13. FIG.
47(f) shows the operational state when the attachment plate 15 is
attached.
[0141] In the second embodiment, the dispersion plate 16, which
includes a plurality of through bores 16a, is disposed between the
distribution plate 12 and the shim plate 13, so the dispersion of
hot melt inside the three-face coating nozzle 210 becomes uniform.
As a result, the coating film thickness of hot melt coated on the
solar cell panel 2 becomes uniform.
[0142] According to the present invention, it is possible to change
the three-face coating nozzles 10 and 210 of the first and second
embodiments to two-face coating nozzles just by replacing the
distribution plate and the shim plate. FIG. 48 and FIG. 49 are,
respectively, front elevation views of a distribution plate 312 and
shim plate 313 for a two-face coating nozzle according to a third
embodiment of the invention.
[0143] The distribution plate 312 includes a cutout 312r for
receiving the solar cell panel 2. Like the distribution plate 12
shown in FIG. 9, the cutout 312r has a width W2 and a length L2. An
L-shaped elongated bore 312a is provided in the distribution plate
312 at the periphery of the cutout 312r. A vertical elongated bore
312a1 is provided in the distribution plate 312 extending upward
from a position facing the outlet opening 11f of the nozzle body 11
when the distribution plate 312 is attached to the nozzle body 11.
Also, an upper lateral elongated bore 312a2 is provided in the
distribution plate 312 extending from the upper end of the vertical
elongated bore 312a1 along the upper side of the cutout 312r. The
elongated bore 312a (312a1, 312a2) has a width W3. A distance D1
defined between the cutout 312r and the elongated bore 312a
determines the length of the flow passage of the slot that
dispenses hot melt. Six holes 312b for passage of attachment screws
are provided in the distribution plate 312.
[0144] The shim plate 313 includes a first cutout 313r for
receiving the solar cell panel 2. The first cutout 313r has a width
W2, an upper side length L3, and a lower side length L2. The width
W2 and the lower side length L2 of the first cutout 313r are
respectively equal to the width W2 and the length L2 of the cutout
312r of the distribution plate 312. The upper side length L3 of the
first cutout 313r is equal to the distance D2 from the left end
312c of the distribution plate 312 to the end of the upper lateral
elongated bore 312a2. However, the dimensions of the first cutout
313r are not limited to this.
[0145] The shim plate 313 also includes a second cutout 313a. The
second cutout 313a communicates with the first cutout 313r. The
second cutout 313a has a width W6 and a length L4. The width W6 is
equal to the length of the vertical elongated bore 312a1 of the
distribution plate 312. The length L4 is equal to the length of the
upper lateral elongated bore 312a2 of the distribution plate 312.
However, the dimensions of the second cutout 313a are not limited
to this. In this embodiment, the dimensions are such that when the
shim plate 313 is adjacent to the distribution plate 312, the
second cutout 313a includes the vertical elongated bore 312a1 and
the upper lateral elongated bore 312a2.
[0146] A step 313s is provided between the first cutout 313r and
the second cutout 313a. The step 313s has a width W7 and a length
L7. The width W7 determines the length of the slot that dispenses
hot melt onto the end face 2e of the solar cell panel 2. The length
L7 is equal to the width W3 of the elongated bore 312a added to the
distance D1 defined between the cutout 312r and the elongated bore
312a of the distribution plate 312. However, the dimensions of the
step 313s are not limited to this. Six holes 313b for passage of
attachment screws are provided in the shim plate 313.
[0147] The distribution plate 312, the shim plate 313, the baffle
plate 14, and the attachment plate 15 are coupled to the nozzle
body 11 by screws 4, thereby forming the two-face coating nozzle. A
slot for coating the end face 2e and upper face 2t (or lower face
2b) of the solar cell panel 2 is formed in the two-face coating
nozzle. Furthermore, the dispersion plate 16 of the second
embodiment may also be inserted between the distribution plate 312
and shim plate 313. In this manner, according to the present
invention, a three-face coating nozzle can be changed to a two-face
coating nozzle just by replacing the distribution plate and the
shim plate.
[0148] Using the coating nozzles of any of the first three
embodiments and the method of FIG. 38, hot melt is dispensed on the
end face 2e and the upper face 2t and/or the lower face 2b of the
solar cell panel 2. FIG. 50 is a view showing the solar cell panel
2 coated with hot melt according to one of the first three
described embodiments. The coating film 3 of hot melt coated on the
upper face 2t and/or the lower face 2b of the solar cell panel 2
creates a coating film overlap portion 3b at the corner 2c of the
panel 2. The coating film overlap portion 3b makes the coating film
non-uniform, and is associated with excess consumption of hot melt.
The multi-face coating device according to a fourth embodiment of
the invention and described below prevents the occurrence of the
coating film overlap portion 3b.
[0149] The multi-face coating device of the fourth embodiment
includes the same elements as the coating device of the first
embodiment, except for the coating nozzle and the inner volume
control valve. Thus, the same reference numbers are applied to the
same elements, and further explanation thereof is omitted. FIG. 51
is an exploded view of a three-face coating nozzle 410 according to
this fourth embodiment of the invention. The three-face coating
nozzle 410 includes a nozzle body 411, a distribution plate 412, a
shim plate 413, and an attachment plate 415. The attachment plate
415 of the fourth embodiment also acts as the baffle plate of the
first embodiment. However, a baffle plate may be provided between
the shim plate 413 and the attachment plate 415. Also, in the same
manner as the second embodiment, a dispersion plate may be inserted
between the distribution plate 412 and the shim plate 413.
[0150] Nozzle Body
[0151] As shown in FIG. 51, the nozzle body 411 is provided with an
inlet opening 411 a supplied with hot melt. FIG. 52 and FIG. 53
are, respectively, a front elevation view and a side elevation view
of the nozzle body 411. The nozzle body 411 is provided with a
cutout 411r for receiving the solar cell panel 2. The nozzle body
411 is provided with a first hot melt passage 411b communicating
with the inlet opening 411a. Also, a cylinder 411c intersecting the
first hot melt passage 411b and communicating with the first hot
melt passage 411b and a junction 411h is provided in the nozzle
body 411. The cylinder 411c is located at the side opposite the
cutout 411r with respect to the first hot melt passage 411b. A
first outlet opening 411f and a second outlet opening 411k for hot
melt are located in the attachment face 411e of the nozzle body
411, to which the distribution plate 412 is attached. The center of
the first outlet opening 411f and the center of the second outlet
opening 411k are separated by a distance D3. The center of the
first outlet opening 411f and the side of the cutout 411r are
separated by a distance D4. The first outlet opening 411f
communicates with the junction 411h via a second hot melt passage
411g. The second outlet opening 411k communicates with the cylinder
411c via a third hot melt passage 411m.
[0152] Distribution Plate
[0153] FIG. 54 is a front elevation view of the distribution plate
412. The distribution plate 412 includes a cutout 412r for
receiving the solar cell panel 2. The cutout 412r has a width W2
and a length L2. The distribution plate 412 is provided with a
U-shaped second elongated bore 412a along the periphery of the
cutout 412r. The second elongated bore 412a, as shown in FIG. 54,
comprises a vertical elongated bore 412a1; an upper lateral
elongated bore 412a2, which extends horizontally from one end of
the vertical elongated bore 412a1 along the upper side of the
cutout 412r; and a lower lateral elongated bore 412a3, which
extends horizontally from the other end of the vertical elongated
bore 412a1 along the lower side of the cutout 412r. The second
elongated bore 412a has a width W3. The upper side of the cutout
412r and the upper lateral elongated bore 412a2 are separated by a
distance D1. Similarly, the lower side of the cutout 412r and the
lower lateral elongated bore 412a3 are separated by a distance D1.
The side of the cutout 412r and the vertical elongated bore 412a1
are separated by a distance D5. The end of the upper lateral
elongated bore 412a2 and the end of the lower lateral elongated
bore 412a3, and the left end 412c of the distribution plate 412 are
separated by a distance D2. A second vertical elongated bore 412d
is provided between the side of the cutout 412r and the vertical
elongated bore 412a1. The second vertical elongated bore 412d is a
linear-shaped elongated bore with a width W3. The length of the
second vertical elongated hole 412d is equal to the width W2 of the
cutout 412r. However, the dimensions of the second vertical
elongated bore 412d are not limited to this.
[0154] The side of the cutout 412r and the second vertical
elongated bore 412d are separated by a distance Dl. The center of
the second vertical elongated bore 412d and the center of the
vertical elongated bore 412a1 are separated by a distance D3. The
center of the second vertical elongated bore 412d and the center of
the cutout 412r are separated by a distance D4. Therefore, when the
distribution plate 412 is attached to the nozzle body 411, the
center of the second vertical elongated bore 412d and the center of
the first outlet opening 411f align, and the center of the vertical
elongated bore 412a1 and the center of the second outlet opening
411k align. The second vertical elongated bore 412d communicates
with the first outlet opening 411f, and the vertical elongated bore
412a1 communicates with the second outlet opening 411k.
[0155] Shim Plate
[0156] FIG. 55 is a front elevation view of the shim plate 413. The
shim plate 413 includes a first cutout 413r1 for receiving the
solar cell panel 2. The first cutout 413r1 has a width W2 and a
length L2. However, in order to communicate with another cutout to
be described later, the width W2 is separated by a distance D2 from
the left end 413c of the shim plate 413. The distance D2 is equal
to the distance D2 between the end of the upper lateral elongated
bore 412a2 and the end of the lower lateral elongated bore 412a3,
and the left end 412c of the distribution plate 412. However, the
dimensions of the first cutout 413r1 are not limited to this.
[0157] The shim plate 413 also includes a second cutout 413r2, a
third cutout 412r3, and a fourth cutout 413r4. The second cutout
413r2, the third cutout 412r3, and the fourth cutout 413r4
respectively communicate with the first cutout 413r1. The second
cutout 413r2 has a width W2 and a length L8. The width W2 is equal
to the width W2 of the first cutout 413r1. Also, the length L8 is
equal to width W3 of the first vertical elongated bore 412d added
to the distance D1 defined between the side of the cutout 412r and
the first vertical elongated bore 412d. However, the dimensions of
the second cutout 413r2 are not limited to this. The second cutout
413r2 forms a first slot 413a1 for working together with the
distribution plate 412 and the attachment plate 415 to dispense hot
melt at the end face 2e of the solar cell panel 2.
[0158] The third cutout 412r3 has a width W8 and a length L8. The
width W8 is equal to the distance D2 subtracted from length L2 of
the first cutout 413r1. Also, the length L8 is equal to the width
W3 of the upper lateral elongated bore 412a2 added to the distance
D1 defined between the upper side of the cutout 412r of the
distribution plate 412 and the upper lateral elongated bore 412a2.
However, the dimensions of the third cutout 412r3 are not limited
to this. The third cutout 413r3 forms a second slot 413a2 for
working together with the distribution plate 412 and the attachment
plate 415 to dispense hot melt at the top face 2t of the solar cell
panel 2. Similarly, the fourth cutout 413r4 has a width W8 and a
length L8. The width W8 is equal to the distance D2 subtracted from
length L2 of the first cutout 413r1. Also, the length L8 is equal
to the width W3 of the lower lateral elongated bore 412a3 added to
the distance D1 defined between the lower side of the cutout 412r
of the distribution plate 412 and the lower lateral elongated bore
412a3. However, the dimensions of the fourth cutout 412r4 are not
limited to this. The fourth cutout 413r4 forms a third slot 413a3
for working together with the distribution plate 412 and the
attachment plate 415 to dispense hot melt at the lower face 2b of
the solar cell panel 2.
[0159] A square baffle part 413s with a side length L8 is formed
between the second cutout 413r2 and the third cutout 413r3, and
also between the second cutout 413r2 and the fourth cutout 413r4.
When the shim plate 413 is attached adjacent to the distribution
plate 412, the second cutout 413r2, the third cutout 412r3, and the
fourth cutout 413r4 communicate directly with the first vertical
elongated bore 412d, the upper lateral elongated bore 412a2, and
the lower lateral elongated bore 412a3 of the distribution plate
412, respectively. The vertical elongated bore 412a1 of the
distribution plate 412 does not communicate directly with any of
the first cutout 413r1, the second cutout 413r2, the third cutout
412r3, or the fourth cutout 413r4 of the shim plate 413.
[0160] Inner Volume Control Valve
[0161] Next, the inner volume control valve attached to the nozzle
body 411 will be described. FIG. 56 is an explanatory view showing
the operation of the inner volume control valve 420 of the fourth
embodiment. The inner volume control valve of the first embodiment
described above has two control positions: a position at which the
tip of the plunger 23 extends, and a retracted position. In
contrast to this, the inner volume control valve 420 of the fourth
embodiment can be controlled to three positions of a first plunger
423. The first plunger 423 is located in the inner volume control
valve 420 so that it can move in a reciprocating manner. One end of
the first plunger 423 is inserted into the cylinder 411c of the
nozzle body 11. The other end of the first plunger 423 is fixed to
a first piston 424. The first piston 424 is located so that it can
move in a reciprocating manner inside a first piston chamber 425 of
the inner volume control valve 420. The first piston 424 divides
the first piston chamber 425 into a first chamber 425a and a second
chamber 425b.
[0162] In the inner volume control valve 420, a second plunger 426
is provided in a plunger chamber 427 so that it can move in a
reciprocating manner. One end of the second plunger 426 can touch
the first piston 424. The other end of the second plunger 426 is
fixed to a second piston 428. The second piston 428 is located so
that it can move in a reciprocating manner inside a second piston
chamber 429 of the inner volume control valve 420. The second
piston 428 divides the second piston chamber 429 into a first
chamber 429a and a second chamber 429b. The second chamber 425b of
the first piston chamber 425 communicates with the plunger chamber
427. A shoulder 430 touching the first piston 428 is formed between
the second chamber 425b of the first piston chamber 425 and the
plunger chamber 427.
[0163] A first inlet/outlet port 431, second inlet/outlet port 432,
and third inlet/outlet port 433 are provided in the inner volume
control valve 420. The first inlet/outlet port 431 communicates
with the first chamber 425a of the first piston chamber 425. In
this regard, the first inlet/outlet port 431 injects air into and
exhausts air from the first chamber 425a. The second inlet/outlet
port 432 communicates with the plunger chamber 427. The plunger
chamber 427 communicates with the second chamber 425b of the first
piston chamber 425, so the second inlet/outlet port 432 injects air
into and exhausts air from the second chamber 425b of the first
piston chamber 425. The third inlet/outlet port 433 communicates
with the second chamber 429b of the second piston chamber 429. In
this regard, the third inlet/outlet port 433 injects air into and
exhausts air from the second chamber 429b. The first chamber 429a
of the second piston chamber 429 also always communicates with a
discharge port 434 and is open to the atmosphere.
[0164] FIG. 56(a) shows the state when air is injected from the
second inlet/outlet port 432 to the second chamber 425b of the
first piston chamber 425, air in the first chamber 425a of the
first piston chamber 425 is exhausted from the first inlet/outlet
port 431, and air in the second chamber 429b of the second piston
chamber 429 is exhausted from the third inlet/outlet port 433.
Because of the pressure difference between the first chamber 425a
and the second chamber 425b of the first piston chamber 425, the
first piston 424 moves so as to shrink the first chamber 425a and
expand the second chamber 425b. The tip of the first plunger 423
extends due to the movement of the first piston 424 and is at a
first position P1.
[0165] FIG. 56(b) shows the state when air is injected from the
third inlet/outlet port 433 to the second chamber 429b of the
second piston chamber 429, air in the first chamber 425a of the
first piston chamber 425 is exhausted from the first inlet/outlet
port 431, and air in the second chamber 425b of the first piston
chamber 425 is exhausted from the second inlet/outlet port 432.
Because of the pressure difference between the first chamber 429a
and the second chamber 429b of the second piston chamber 429, the
second piston 428 moves so as to shrink the first chamber 429a and
expand the second chamber 429b. The second plunger 426 extends due
to the movement of the second piston 428. The first chamber 425a
and the second chamber 425b of the first piston chamber 425 are
exhausted, so the pressure difference is not applied to the first
piston 424. However, the pressure of hot melt is applied to the
first plunger 423 inserted in the cylinder 411 c of the nozzle body
411, so the first plunger 423 moves until the first piston 424
touches the second plunger 426. The tip of the first plunger 423
retracts by a distance D6 from the first position P1, and is at a
second position P2. The second position P2 is near a second
junction where the third hot melt passage 411m joins the cylinder
411c, and where the second outlet opening 411k communicates with
the cylinder 411c.
[0166] FIG. 56(c) shows the state when air is injected from the
first inlet/outlet port 431 to the first chamber 425a of the first
piston chamber 425, air in the second chamber 425b of the first
piston chamber 425 is exhausted from the second inlet/outlet port
432, and air in the second chamber 429b of the second piston
chamber 429 is exhausted from the third inlet/outlet port 433.
Because of the pressure difference between the first chamber 425a
and the second chamber 425b of the first piston chamber 425, the
first piston 424 moves so as to expand the first chamber 425a and
shrink the second chamber 425b. In conjunction with the movement of
the first piston 424, the second plunger 426, which is touching the
first piston 424, also moves. The tip of the first plunger 423
retracts by a distance D7 from the second position P2, and is at a
third position P3. At this time, the first piston 424 touches the
shoulder 430.
[0167] FIGS. 57(a)-57(c) collectively are a view showing the
positional relationship between the first outlet opening 411f and
the second outlet opening 411k and the first plunger 423 of the
nozzle body 411. FIG. 57(a) shows the state when the first plunger
423 extends and is at the first position P1. When the first plunger
423 is at the first position P1, the first plunger 423 blocks the
second outlet opening 411k and allows hot melt to flow only to the
first outlet opening 411f. Thus, hot melt is dispensed only from
the first outlet opening 411f. The first outlet opening 411f
communicates with the second cutout 413r2 of the shim plate 413 via
the first vertical elongated bore 412d of the distribution plate
412. Therefore, hot melt can be dispensed onto only the end face 2e
of the solar cell panel 2 from the first slot 413a1. More
specifically, one-face coating can be performed.
[0168] FIG. 57(b) shows the state when the first plunger 423
retracts by a distance D6 from the first position P1 and is at the
second position P2. The distance D6 is essentially equal to the
distance between the center of the first outlet opening 411f and
the center of the second outlet opening 411k. However, the distance
D6 is not limited to this. For example, the distance D6 may be
longer than the distance between the first outlet opening 411f and
the second outlet opening 411k. Therefore, hot melt is dispensed
from the first outlet opening 411f and the second outlet opening
411k. The second outlet opening 411k communicates with the third
cutout 412r3 and fourth cutout 413r4 of the shim plate 413 via the
vertical elongated bore 412a1, the upper lateral elongated bore
412a2, and the lower lateral elongated bore 412a3 of the
distribution plate 412. Therefore, hot melt from the second outlet
opening 411k can be coated onto the upper face 2t and lower face 2b
of the solar cell panel 2 from the second slot 413a2 and the third
slot 413a3. Hot melt from the first outlet opening 411f is
dispensed on the end face 2e, so three-face coating can be
performed.
[0169] FIG. 57(c) shows the state when the first plunger 423
retracts by a distance D7 from the second position P2 and is at the
third position P3. The valve rod 35 of the hot melt supply valve 30
attached to the nozzle body 410 touches the valve seat 36, and
dispensing of hot melt is prevented. In this state, the first
plunger 423 is retracted from the second position P2 to the third
position P3. The first plunger 423 improves termination when
dispensing stops by sucking hot melt back into the cylinder 411c.
The distance D7 is selected so as to expand the volume of the hot
melt passage by exactly the appropriate amount.
[0170] Operation of Hot Melt Supply Valve and Inner Volume Control
Valve
[0171] FIGS. 58(a)-58(c) collectively are an explanatory view
showing the operation of the first plunger 423 and the hot melt
supply valve 30 of the inner volume control valve 420 of the fourth
embodiment. FIGS. 58(a)-58(c) schematically show the hot supply
valve 30 and the nozzle body 411 for explanation.
[0172] FIG. 58(a) is a view showing the state before starting to
dispense hot melt and after dispensing ends. One end of the valve
rod 35 of the hot melt supply valve 30 touches the valve seat 36,
and closes the dispensing port 34. Therefore, dispensing of hot
melt inside the hot melt chamber 32 from the dispensing port 34 is
prevented. The first plunger 423 of the inner volume control valve
420 is at the third position P3, the most pulled-back state.
[0173] FIG. 58(b) is a view showing the state during three-face
coating of hot melt. The valve rod 35 of the hot melt supply valve
30 separates from the valve seat 36, and opens the dispensing port
34. At the same time, the first plunger 423 extends to the second
position P2, and reduces the volume inside the cylinder 411c. Hot
melt inside the hot melt chamber 32 is dispensed from the
dispensing port 34 to the inlet opening 411a of the nozzle body
411. Hot melt passes through the first hot melt passage 411b, the
junction 411h, and the second hot melt passage 411g, and is then
dispensed from the first outlet opening 411f. Similarly, hot melt
passes through the first hot melt passage 411b, the junction 411h,
the cylinder 411c, and the third hot melt passage 411m, and is
dispensed from the second outlet opening 411k. Therefore, hot melt
is coated on the end face 2e, the upper face 2t, and the lower face
2b of the solar cell panel 2 from the first, second, and third
slots 413a1, 413a2, and 413a3, respectively.
[0174] When starting three-face dispensing from the state shown in
FIG. 58(a), the valve rod 35 separates from the valve seat 36 and
opens the dispensing port 34; at the same time, the first plunger
423 extends from the third position P3 to the second position P2.
When ending the dispensing, the valve rod 35 touches the valve seat
36 and closes the dispensing port 34; at the same time, the first
plunger 423 retracts to the third position P3, increases the volume
of the cylinder 411c, and sucks hot melt in the hot melt passage
back into the cylinder 411c. This improves termination when
dispensing ends.
[0175] FIG. 58(c) is a view showing the state during one-face
coating of hot melt. The valve rod 35 of the hot melt supply valve
30 separates from the valve seat 36, and opens the dispensing port
34. At the same time, the first plunger 423 extends to the first
position P1, and reduces the volume inside the cylinder 411c. Hot
melt inside the hot melt chamber 32 is dispensed from the
dispensing port 34 to the inlet opening 411a of the nozzle body
411. Hot melt passes through the first hot melt passage 411b, the
junction 411h, and the second hot melt passage 411g, and is
dispensed from the first outlet opening 411f. However, the third
hot melt passage 411m is closed by the first plunger 423, so hot
melt is not dispensed from the second outlet opening 411k.
[0176] When starting one-face dispensing from the state shown in
FIG. 58(a), the valve rod 35 separates from the valve seat 36 and
opens the dispensing port 34; at the same time, the first plunger
423 extends from the third position P3 to the first position P1.
When starting one-face dispensing from the state shown in FIG.
58(b), the first plunger 423 extends from the second position P2 to
the first position P1. When starting three-face dispensing from the
state shown in FIG. 58(c), the first plunger 423 is retracted from
the first position P1 to the second position P2. When ending
dispensing from the state shown in FIG. 58(c), the valve rod 35
touches the valve seat 36 and closes the dispensing port 34; at the
same time, the first plunger 423 retracts to the third position P3,
increases the volume of the cylinder 411c, and sucks hot melt in
the hot melt passage into the cylinder 411c. This improves
termination when dispensing ends.
[0177] The multi-face coating device of the fourth embodiment is a
three-face coating device with a variable coating range function.
Below, the operation of a three-face coating device 401 with a
variable coating range function will be described.
[0178] Before and After Dispensing, i.e. Coating Stopped State
[0179] FIG. 59 is a view showing the inner volume control valve 420
and the hot melt supply valve 30 before dispensing hot melt and
after dispensing hot melt with the three-face coating device 401 of
the fourth embodiment with a variable coating range function. The
same elements as the three-face coating device 1 of the first
embodiment are assigned the same reference numbers, and further
explanation thereof is omitted.
[0180] In the hot melt coating stopped state, and more
specifically, before and after dispensing hot melt, the valve air
control circuit 60 supplies air to the first chamber 425a of the
first piston 425 via the air passage 52, the speed controller 22,
and the first inlet/outlet port 431. Meanwhile, air in the second
chamber 425b of the first piston chamber 425 is delivered to the
valve air control circuit 60 via the second inlet/outlet port 432,
the speed controller 421, and the air passage 451, and is then
exhausted to the atmosphere from the valve air control circuit 60.
The pressure inside the first chamber 425a is higher than the
pressure inside the second chamber 425b, so the first piston 424
moves so as to enlarge the first chamber 425a and shrink the second
chamber 425b. The first piston 424 touches the second plunger 426
of the second piston 428. Air inside the second chamber 429b of the
second piston chamber 429 is delivered to the valve air control
circuit 60 via the third inlet/outlet port 433, the speed
controller 21, and the air passage 51, and is then exhausted to the
atmosphere from the valve air control circuit 60. Therefore,
because of the movement of the first piston 424, the second piston
428 moves so as to enlarge the first chamber 429a of the second
piston chamber 429 and shrink the second chamber 429b. Also,
because of the movement of the first piston 424, the first plunger
423 retracts to the third position P3 inside the cylinder 411c of
the nozzle body 411. At this time, the first plunger 423 sucks the
hot melt that is in the hot melt passages 411b, 411g, and 411m back
into the cylinder 411c.
[0181] Furthermore, the speed controllers 22 and 421, as aperture
valves, control the movement speed of the first piston 424 by
adjusting the flow of air. Similarly, the speed controller 21
controls the movement speed of the second piston 428 by adjusting
the flow of air. Before and after dispensing hot melt, the gun air
control circuit 90 releases air in the first chamber 38a of the
piston chamber 38 to the atmosphere via the air passage 55 and the
air passage 42 of the gun 40. The piston 37 is pushed by the
energizing force of the spring 39, touches one end of the valve rod
35 to the valve seat 36, and closes the dispensing port 34.
Therefore, dispensing of hot melt inside the hot melt chamber 32
from the dispensing port 34 is prevented.
[0182] During Three-face Coating
[0183] FIG. 60 is a view showing the inner volume control valve 420
and the hot melt supply valve 30 during three-face coating by the
three-face coating device 401 of the fourth embodiment with a
variable coating range function. During three-face coating, the
control device 110 controls the valve air control circuit 60 using
the first air control signal 111, and supplies air from the air
supply source 70 to the air circuit 51. Air is supplied to the
second chamber 429b of the second piston chamber 429 via the air
passage 51, the speed controller 21, and the third inlet/outlet
port 433. Meanwhile, the first chamber 429a of the second piston
chamber 429 is always released to the atmosphere via the exhaust
port 434. Therefore, the first chamber 429a shrinks and the second
chamber 429b expands as the second piston 428 moves. Also, the
valve air control circuit 60 releases air in the first chamber 425a
and the second chamber 425b of the first piston chamber 425 to the
atmosphere. Therefore, because of the movement of the second piston
428, the second plunger 426 pushes the first piston 424, and the
first plunger 423 extends to the second position P2.
[0184] The control device 110 controls the gun air control circuit
90 using the second air control signal 112, such that the control
rod 35 separates from the valve seat 36 and the dispensing port 34
opens. Hot melt in the hot melt chamber 32 is dispensed from the
dispensing port 34 to the inlet opening 411 a of the nozzle body
411. Hot melt passes through the first hot melt passage 411b, and
is dispensed from the first outlet opening 411f and the second
outlet opening 411k. Therefore, hot melt is coated on the end face
2e, the upper face 2t, and the lower face 2b of the solar cell
panel 2 from the first slot 413a1, the second slot 413a2, and the
third slot 413a3, respectively.
[0185] During One-face Coating
[0186] FIG. 61 is a view showing the inner volume control valve 420
and the hot melt supply valve 30 during one-face coating by the
three-face coating device 401 of the fourth embodiment with a
variable coating range function. During one-face coating, the
control device 110 controls the valve air control circuit 60 using
the first air control signal 111, and supplies air from the air
supply source 70 to the air circuit 41. Air is supplied to the
second chamber 425b of the first piston chamber 425 via the air
passage 451, the speed controller 421, and the second inlet/outlet
port 432. Meanwhile, the first chamber 425a of the first piston
chamber 425 is released to the atmosphere by the valve air control
circuit 60. Therefore, the first chamber 425a shrinks and the
second chamber 425b expands as the first piston 424 moves. Because
of the movement of the first piston 424, the first plunger 423
extends to the first position P1. The first plunger 423 blocks the
third hot melt passage 411m to the second outlet opening 411k of
the nozzle body 411, so dispensing hot melt from the second outlet
opening 411k is prevented. Hot melt is dispensed only from the
first outlet opening 411f. Therefore, hot melt is dispensed only on
the end face 2e of the solar cell panel 2 from the first slot
413a1.
[0187] Coating Methods
[0188] FIG. 62 to FIG. 64 are explanatory views showing methods of
coating the solar cell panel 2 using the three-face coating device
(hereinafter "coating device") 401 with a variable coating range
function, mounted on a robot arm.
[0189] In the coating method shown in FIG. 62, at a corner 2c1 of
the panel 2, the coating device 401 changes from the coating
stopped state shown in FIG. 59 to the three-face coating state
shown in FIG. 60. While the coating device 401 is moved in the
direction indicated by arrow A1 by the robot arm, it coats hot melt
403a on the upper face, the end face, and the lower face of the
panel 2 from the corner 2c1 to a corner 2c2. At the corner 2c2, the
coating device 401 is temporarily in a coating stopped state. Next,
when coating hot melt 403b from the corner 2c2 to a corner 2c3, the
end face 2e of the corner 2c2 receives one-face coating for exactly
the distance W8 so that hot melt is not coated so as to overlap on
the upper face and the lower face of the corner 2c2. The distance
W8 is the width of the coating film of hot melt dispensed on the
upper face and lower face; the distance W8 is also the width W8 of
the third and fourth cutouts 413r3 and 413r4 of the shim plate
413.
[0190] In this regard, the coating device 401 changes from the
coating stopped state to the one-face coating state shown in FIG.
61 at the corner 2c2. While the coating device 401 is moved in the
direction indicated by arrow A2 by the robot arm, it coats one
face, the end face 2e of the panel 2, for exactly the distance W8.
Then the coating device 401 goes into three-face coating and
performs three-face coating until the corner 2c3. At the corner
2c3, the coating device 401 temporarily is in a coating stopped
state. In the same manner, while being moved in the direction
indicated by arrow A3 from the corner 2c3 to a corner 2c4, the
coating device 401 performs one-face coating and three-face coating
of hot melt 403c. When coating from the corner 2c4 to the corner
2c1, the coating device 401, while being moved in the direction
indicated by arrow A4, performs one-face coating of hot melt 403d
for exactly the distance W8 from the corner 2c4, and subsequently
performs three-face coating. It switches to one-face coating before
corner 2c1, and performs one-face coating for exactly the distance
W8 to corner 2c1. Using the coating device 401 in this manner
prevents hot melt from overlapping on the upper face and lower face
at the corners 2c1, 2c2, 2c3, and 2c4.
[0191] FIG. 63 and FIG. 64 show other coating methods. In the
coating method shown in FIG. 63, at the corner 2c1 of the panel 2,
the coating device 401 changes from the coating stopped state shown
in FIG. 59 to the one-face coating state shown in FIG. 61. While
the coating device 401 is moved in the direction indicated by arrow
A1 by the robot arm, the coating device 401 dispenses hot melt 403a
on the end face 2e of the panel 2 for exactly a distance W8 from
the corner 2c1. This procedure is performed to ensure coating
without overlapping at the upper face and the lower face of the
corner 2c1. After the distance W8 from the corner 2c1, the coating
device 401 changes from the one-face coating state to the
three-face coating state shown in FIG. 60, and dispenses hot melt
403a on the upper face, end face, and lower face of the panel 2. At
the corner 2c2 the coating device 401 temporarily is in a coating
stopped state. Next, when the coating device 401 coats from the
corner 2c2 to the corner 2c3, the end face 2e of the corner 2c2
receives one-face coating with hot melt 403b for exactly a distance
W8 so that hot melt is not overlapping at the upper face and the
lower face of the corner 2c2. When the distance W8 is exceeded, the
coating device 401 changes to three-face coating. In the same
manner, when dispensing hot melt 403c from the corner 2c3 to the
corner 2c4, the coating device 401 performs one-face coating for
exactly a distance W8 from the corner 2c3 and then three-face
coating for the remainder. When dispensing hot melt 403d from the
corner 2c4 to the corner 2c1, the coating device 401 similarly
performs one-face coating for exactly a distance W8 from the corner
2c4 and then three-face coating for the remainder. In this manner,
hot melt coating is prevented from overlapping on the upper face
and the lower face at the corners 2c1, 2c2, 2c3, and 2c4 of the
panel 2.
[0192] In the coating method shown in FIG. 64, at the corner 2c1 of
the panel 2, the coating device 401 changes from the coating
stopped state shown in FIG. 59 to the three-face coating state
shown in FIG. 60. The coating device 401, while being moved in the
direction of arrow A1 by the robot arm, dispenses hot melt 403a on
the upper face, the end face, and the lower face of the panel 2
from the corner 2c1 until a distance W8 before the corner 2c2. At
the distance W8 before the corner 2c2, the coating device 401
changes from the three-face coating state to the one-face coating
state shown in FIG. 61, and dispenses hot melt 403a only onto the
end 2e of the panel 2 until the corner 2c2. At the corner 2c2, the
coating device 401 temporarily is in a coating stopped state. Next,
in the same manner, the coating device 401, while being moved in
the direction of arrow A2, dispenses hot melt 403b on three faces
from the corner 2c2 until a distance W8 before the corner 2c3, and
during the distance W8 until the corner 2c3, the coating device 401
performs one-face coating of hot melt 403b. In the same manner, the
coating device 401, while being moved in the direction of arrow A3,
dispenses hot melt 403c on three faces from the corner 2c3 until a
distance W8 before the corner 2c4, and during the distance W8 until
the corner 2c4, the coating device 401 performs one-face coating of
hot melt 403c. In the same manner, the coating device 401, while
being moved in the direction of arrow A4, dispenses hot melt 403d
on three faces from the corner 2c4 until a distance W8 before the
corner 2c1, and during the distance W8 until the corner 2c1, the
coating device 401 performs one-face coating of hot melt 403d. In
this manner, hot melt coating is prevented from overlapping on the
upper face and the lower face at the corners 2c1, 2c2, 2c3, and 2c4
of the panel 2.
[0193] FIGS. 65(a)-65(c) collectively are an explanatory view
showing a method of performing coating using two three-face coating
devices 401A and 401 B with a variable coating range function. Hot
melt 403 is simultaneously coated by the two coating devices 401A
and 401 B on two opposite edges of the solar cell panel 2. This
operation can increase productivity. The two coating devices 401A
and 401 B are respectively connected to the hot melt supply source
80 by supply hot melt passages 54. The valve air control circuit 60
and the gun air control circuit 90 are respectively connected to
the inner volume control valves and hot melt supply valves of the
coating devices 401 A and 401 B. The valve air control circuit 60
and the gun air control circuit 90 are connected to the air supply
source 70 by air passages 53 and 56, respectively.
[0194] As shown in FIG. 65(a), the two opposite edges of the solar
cell panel 2 are respectively passed through the two coating
devices 401A and 401 B. While the solar cell panel 2 is moved in
the direction of arrow 01, hot melt 403 is dispensed from the two
coating devices 401 A and 401 B onto two opposite edges of the
panel. When coating the two ends of the panel 2, the panel 2 is
rotated 90.degree. clockwise in the direction of arrow C2 as shown
in FIG. 65(b). When doing so, it is necessary to ensure space for
the panel 2 to rotate, so the coating device 401 B may retract by
moving in the direction indicated by arrow Bl. Next, as shown in
FIG. 65(c), the panel 2 is moved in the direction indicated by
arrow C3. The direction indicated by arrow C3 is the opposite of
the direction indicated by arrow C1. While the solar cell panel 2
is moved in the direction of arrow C3, hot melt 403 is dispensed
from the two coating devices 401 A and 401 B onto another two
opposite edges of the panel 2.
[0195] In this manner, panel coating is completed with two
dispensing steps and one panel rotation step, so productivity can
be increased. Furthermore, the step of dispensing hot melt onto
another two opposite edges of the panel 2 is as follows: one-face
coating of hot melt on only the panel end face from one corner of
the panel to a first position separated by a width W8, which is the
width of the hot melt coated on the panel face; and then three-face
coating between the first position and a second position a width W8
before the other corner of the panel; and then one-face coating of
hot melt on only the panel end face from the second position to the
other corner of the panel.
[0196] FIG. 66 is an explanatory view showing a method of
performing coating using four three-face coating devices 401A,
401B, 401C, and 401D with a variable coating range function. Hot
melt 403 is simultaneously coated by the two coating devices 401A
and 401B on two opposite edges of the solar cell panel 2. Next, hot
melt 403 is simultaneously coated by the two coating devices 401C
and 401 D on another two opposite edges of the panel 2. This
operation can increase productivity.
[0197] The four coating devices 401A, 401B, 401C, and 401D are
respectively connected to the hot melt supply source 80 by supply
hot melt passages 54. The valve air control circuit 60 and the gun
air control circuit 90 are respectively connected to the inner
volume control valves and hot melt supply valves of the coating
devices 401A, 401B, 401C, and 401D. The valve air control circuit
60 and the gun air control circuit 90 are connected to the air
supply source 70 by air passages 53 and 56 respectively. As shown
in FIG. 66, while the solar cell panel 2 is moved along a first
path in the direction indicated by arrow C4, the two opposite edges
of the panel 2 are respectively passed through the two coating
devices 401A and 401 B and hot melt 403 is dispensed on the two
opposite edges of the panel 2 from the two coating devices 401A and
401 B. When coating the two ends of the panel 2, the panel 2 is
moved along a second path in the direction indicated by arrow C5,
which is orthogonal to the direction indicated by arrow C4. In this
regard, the second path is orthogonal to the first path. While the
panel 2 is moved in the direction indicated by arrow C5, hot melt
403 is dispensed on another two opposite edges of the panel 2 from
the two coating devices 401C and 401 D.
[0198] In this manner, just by changing the movement direction of
the panel, panel coating is complete with two dispensing steps, so
productivity can be increased. Furthermore, the step of dispensing
hot melt onto another two opposite edges of the panel 2 is as
follows: one-face coating of hot melt on only the panel end face
from one corner of the panel to a first position separated by a
width W8, which is the width of the hot melt coated on the panel
face; and then three-face coating between the first position and a
second position a width W8 before the other corner of the panel;
and then one-face coating of hot melt on only the panel end face
from the second position the other corner of the panel.
[0199] The fourth embodiment included a coating device that used
the inner volume control valve 420 capable of three-position
control, with the three-face coating nozzle 410 as an example.
However, the inner volume control valve 420 capable of
three-position control may also be used in the two-face coating
nozzle presented in the third embodiment. In this case, it is also
possible to switch between one-face coating on the end face of the
panel and two-face coating on the upper face and end face of the
panel. Switching between one-face coating and two-face coating
prevents hot melt from overlapping at the corners of the panel.
[0200] Also, an inner volume control valve capable of four-position
or five-position or more position control may be provided by
serially disposing two or more second plungers in the inner volume
control valve 420 capable of three-position control. In this case,
if the nozzle body, the distribution plate, and the shim plate are
appropriately configured, hot melt may be dispensed in a controlled
manner from many slots.
[0201] According to the embodiments of the present invention, it is
possible to provide a multi-face coating nozzle that can dispense a
liquid such as an adhesive or sealant at the end face of a
substrate such as a solar cell panel and at two or more faces such
as at the upper peripheral face and/or the rear peripheral face
adjacent to the end face.
[0202] The present invention is not limited to the above
embodiments. It can be practiced in various other configurations
without departing from its characteristic matters. Therefore, the
previously described embodiments are merely simple illustrative
examples in every point, and are not to be interpreted as limiting.
The scope of the present invention is as indicated by the claims,
and is not restricted in any way by the specification body. In
addition, variations and modifications that belong to the same
scope as the claims are all within the scope of the present
invention. What is claimed is:
* * * * *