Lay-up apparatus

Abstract

A lay-up apparatus lays first and second strips of tape 101, 102 on top of two electrodes 5, 6 deposited on a photovoltaic device panel 1. The strips of tape are unwound by first and second grippers 112, 122 and cut to predetermined lengths by first and second cutters 113, 123. The cut strips of tape are laid one on top of the other and transported by rotatable moving means 130. The moving means 130 rotates in opposite directions when laying the strips of tape it holds from the electrode 5 toward the electrode 6 and when laying the strips of tape from the electrode 6 toward the electrode 5, while using one end of the strips of tape as a reference and keeping constant the relative positions of the reference end of the strips of tape and that electrode which is nearest the reference end.

What is claimed is: 
     
         1 . A lay-up apparatus for laying tape between two strips of electrodes on a flat photovoltaic device panel separate from but parallel to each other so that the tape extends from each strip of electrodes toward the other strip of electrodes, the lay-up apparatus comprising:
 a first reel holder comprising:
 a first reel around which a first strip of tape is wound; 
 a first fixed gripper that alternately grips and releases the first strip of tape; 
 a first movable gripper to grip the first strip of tape to unwind the first strip of tape from the first reel around which the first strip of tape is wound; and 
 a first cutter disposed between the first fixed gripper and the first movable gripper to cut the first strip of tape when the first movable gripper unwinds a predetermined length of the first strip of tape from the first reel; 
   a first supporting cradle that is reciprocally vertically movable, disposed beneath the first cutter and the first movable gripper, and provided with multiple vacuum holes to suctionally attract the first strip of tape to the first cradle after the first cutter cuts the first strip of tape; and   moving means comprising a plurality of vacuum chucks on a bottom thereof to suctionally grip the tape,   the moving means being capable of three-dimensional movement while supporting the cut first strip of tape, rotatable about an axis perpendicular to the flat photovoltaic device panel, and configured to grip and rotate the first strip of tape in opposite directions when laying the first strip of tape from one of the two parallel strips of electrodes toward the other of the two parallel strips of electrodes to keep constant relative positions of one end of the first strip of tape serving as a reference point and the strip of electrodes nearer the end of the first strip of tape serving as a reference point.   
     
     
         2 . The lay-up apparatus according to  claim 1 , further comprising:
 a second reel holder comprising:
 a second reel around which a second strip of tape is wound; 
 a second fixed gripper that alternately grips and releases the second strip of tape; 
 a second movable gripper to grip the second strip of tape to unwind the second strip of tape from the second reel around which the second strip of tape is wound; and 
 a second cutter disposed between the second fixed gripper and the second movable gripper to cut the second strip of tape when the second movable gripper unwinds a predetermined length of the second strip of tape from the second reel; and 
   a second supporting cradle that is reciprocally vertically movable, disposed beneath the second cutter and the second movable gripper, and provided with multiple vacuum holes to suctionally attract the second strip of tape to the second cradle after the second cutter cuts the second strip of tape,   wherein the moving means overlays the first strip of tape onto the second strip of tape such that the first strip of tape overlaps the second strip of tape, which lies between the first strip of tape and the vacuum chucks on the bottom of the moving means.   
     
     
         3 . The lay-up apparatus according to  claim 2 , wherein, when the moving means overlays the first strip of tape onto the second strip of tape such that the first strip of tape overlaps the second strip of tape, an end of the second strip of tape cut by the second cutter projects a predetermined length beyond an end of the first strip of tape cut by the first cutter. 
     
     
         4 . The lay-up apparatus according to  claim 2 , wherein the moving means grasps both the first strip of tape and the second strip of tape, overlays the first strip of tape onto the second strip of tape, and then simultaneously lays both the first strip of tape and the second strip of tape on the photovoltaic device panel. 
     
     
         5 . The lay-up apparatus according to  claim 2 , wherein the first strip of tape and the second strip of tape are laid separately on the photovoltaic device panel one strip at a time. 
     
     
         6 . The lay-up apparatus according to  claim 2 , further comprising a numerical control device to control movement of the first and second movable grippers, the first and second cutters, the first and second supporting cradles, and the moving means. 
     
     
         7 . The lay-up apparatus according to  claim 2 , wherein:
 the first strip of tape is insulating material; and   the second strip of tape is copper foil.   
     
     
         8 . A lay-up method of laying tape between two strips of electrodes on a flat photovoltaic device panel separate from but parallel to each other so that the tape extends from each strip of electrodes toward the other strip of electrodes, the method comprising the steps of:
 gripping and unwinding a first strip of tape and a second strip of tape to unwind the first and second strips of tape from first and second reels around which the first and second strips of tape are wound, respectively;   cutting the first and second strips of tape to a predetermined length;   suctionally attracting the first strip of tape to a first cradle and the second strip of tape to a second cradle;   gripping and rotating the first and second strips of tape in opposite directions when laying the first and second strips of tape from one of the two parallel strips of electrodes toward the other of the two parallel strips of electrodes to keep constant relative positions of one end of the first strip of tape serving as a reference point and the strip of electrodes nearer the end of the first strip of tape serving as a reference point;   overlaying the first strip of tape onto the second strip of tape so that the first strip of tape overlaps the second strip of tape in such a way that one end of the second strip of tape projects a predetermined length beyond a corresponding end of the first strip of tape;   laying the first strip of tape and the second strip of tape on the photovoltaic device panel.   
     
     
         9 . The lay-up method according to  claim 8 , wherein both the first strip of tape and the second strip of tape are laid on the photovoltaic device panel simultaneously. 
     
     
         10 . The lay-up method according to  claim 8 , wherein the first strip of tape and the second strip of tape are laid separately on the photovoltaic device panel one strip at a time. 
     
     
         11 . The lay-up method according to  claim 8 , further comprising the steps of:
 provisionally fixing the first and second strips of tape in place on the photovoltaic device panel at multiple locations with adhesive tape once the first and second strips of tape are laid on the photovoltaic device panel; and   bending upward at substantially right angles ends of the second strip of tape nearest a junction box of the photovoltaic device panel.   
     
     
         12 . The lay-up method according to  claim 8 , wherein:
 the first strip of tape is insulating material; and   the second strip of tape is copper foil.