Laminating device and laminating method

Abstract

The present invention belongs to the field of solar cell technology, and specifically relates to a lamination device and method. The lamination device of the present invention comprises: an infeed conveyor unit, a lamination unit, a discharge conveyor unit, and a control unit. A first sensor and a second sensor are respectively disposed on the discharge conveyor unit at intervals of M photovoltaic modules, where M ≥ 1. The first and second sensors can detect the number N1 and N2 of modules passing through their locations and transmit these values to the control unit. The control unit compares N1 and N2. When N1 > N2, it issues a control instruction to the lamination unit to extend the lamination time and continuously laminate the modules. The present invention improves the intelligent responsiveness of the lamination device during the lamination process and reduces the yield loss of modules within the lamination chamber of the lamination unit caused by module accumulation.

Description

Technical Field

[0001] The invention belongs to the technical field of solar cells and relates to a lamination device and a lamination method. Background Art

[0002] Lamination is a crucial step in the photovoltaic module production process. A laminator bonds photovoltaic glass, encapsulation materials, cells, encapsulation materials, and backsheet or backsheet glass together under specific temperature, pressure, and vacuum conditions to form a photovoltaic module. A complete lamination system consists of three components: an infeed conveyor unit, a laminator, and a discharge conveyor unit. Lamination also takes the longest time of any front-end process.

[0003] Once the components within the laminator chamber are laminated, the chamber opens and the components are conveyed out for cooling. However, due to the high production volume of components on the production line, the existing lamination process often sees component accumulation in the discharge conveyor unit. Once components accumulate in the discharge conveyor unit, they cannot be discharged and must remain in the lamination chamber. As the retention time increases, the laminated components are trapped in the laminator chamber and cannot be discharged for timely cooling. This can lead to batch defects or even outright scrapping of components, severely reducing the component yield and significantly increasing the component production cost. Summary of the Invention

[0004] In response to the above technical problems, the present invention provides a lamination device that can quickly identify whether there is component stacking in the discharge conveying unit of the lamination process. When component stacking occurs, the lamination time is extended, thereby reducing the component defect rate caused by the components staying in the chamber for too long.

[0005] Another aspect of the present invention provides a lamination method.

[0006] To this end, the present invention adopts the following technical solutions:

[0007] A laminating device, characterized in that it includes: a feed conveying unit, a laminating unit, a discharge conveying unit and a control unit. A first sensor and a second sensor are respectively arranged on the discharge conveying unit at a distance of M photovoltaic modules, where M ≥ 1. The first sensor and the second sensor can detect the number N1 and N2 of modules passing through their positions and transmit the values to the control unit. The control unit compares N1 and N2. When N1>N2, it issues a control instruction to make the laminating unit extend the lamination time and continuously laminate the modules.

[0008] Furthermore, the first sensor and the second sensor may be infrared sensors, visual recognition devices, pressure sensors or position sensors.

[0009] Furthermore, M≥2.

[0010] Furthermore, the first sensor and the second sensor are respectively located at the feed end and the discharge end of the discharge conveying unit.

[0011] Furthermore, the laminating unit is a laminator.

[0012] Another aspect of the present invention provides a lamination method, wherein a plurality of solar cells are laminated to form a photovoltaic module using a lamination device. The lamination device includes a feed conveying unit, a lamination unit, a discharge conveying unit, and a control unit. A first sensor and a second sensor are respectively provided on the discharge conveying unit at a distance of M photovoltaic modules, where M is greater than or equal to 1. The lamination method includes the following steps:

[0013] S1: The first sensor and the second sensor respectively detect the number of components passing through their positions, record them as N1 and N2 respectively, and upload the values N1 and N2 to the control unit in real time.

[0014] S2: The control unit compares the sizes of N1 and N2. When N1=N2, a control instruction is issued, the lamination device operates normally, and the component is laminated in the lamination unit for the first set time T1; when N1>N2, a control instruction is issued to make the lamination unit extend the lamination time, and the extended time lasts for the second time T2, and the component is continuously laminated.

[0015] Furthermore, the first sensor and the second sensor may be infrared sensors, visual recognition devices, pressure sensors or position sensors.

[0016] Furthermore, M≥2.

[0017] Furthermore, the first sensor and the second sensor are respectively located at the feed end and the discharge end of the discharge conveying unit.

[0018] Furthermore, the laminating unit is a laminator.

[0019] The present invention improves lamination equipment and methods by installing a sensor on the discharge conveyor unit that can sense the number of components. By comparing the number of components at the feed and discharge ends of the discharge conveyor unit, it is determined whether there is component accumulation in the subsequent process of the lamination device. If component accumulation exists, the lamination time of the lamination unit is extended to continuously laminate the components.

[0020] In the prior art, when component backlogs occur on the production line, causing laminates to remain in an open lamination chamber, the high temperature can cause defects such as bulging of the backplane or bubbles. However, the present invention effectively prevents component defects by keeping the lamination chamber open and extending the lamination time of the lamination unit.

[0021] Compared with the existing technology, the advantages of the present invention are:

[0022] The intelligent response degree of the lamination device in the lamination process is improved, and the yield loss of components in the lamination chamber of the lamination unit caused by component accumulation is reduced.

[0023] Other advantages, objectives and features of the present invention will be reflected in part through the following description, and in part will be understood by those skilled in the art through study and practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 It is a schematic diagram of the present invention.

[0025] In the figure: a feed conveying unit 1, a laminating unit 2, a discharge conveying unit 3, a feed end 3a of the discharge conveying unit, a discharge end 3b of the discharge conveying unit, a first sensor 4, a second sensor 5, a laminate 100, and a photovoltaic module 101. DETAILED DESCRIPTION

[0026] In order to enable those skilled in the art to better understand the solutions of the present invention, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the accompanying drawings in the embodiments of the present invention.

[0027] A key step in the process of converting solar cells into photovoltaic modules is the lamination process. This process involves heating and pressing the EVA (Evaporated Vapor) film attached to the photovoltaic module, bonding the cells, glass, and backsheet / glass together to form the photovoltaic module. Therefore, the photovoltaic module before lamination is called a laminate, and after lamination is completed, it is called a photovoltaic module or module.

[0028] Example 1

[0029] like Figure 1 As shown, this embodiment provides a laminating device, which includes, in order from the conveying direction of the material (i.e., the laminate 100), an infeed conveying unit 1, a laminating unit 2, an outfeed conveying unit 3, and a control unit. The laminating unit 2 adopts a laminating machine in the prior art, and the infeed conveying unit 1 and the outfeed conveying unit 3 adopt existing laminating machine conveying devices.

[0030] On the discharging conveying unit, a first sensor and a second sensor are respectively arranged at a certain distance apart, and the distance between the sensors is at least the distance of a photovoltaic module. The so-called "distance of a photovoltaic module" here refers to the distance between two opposite sides of the photovoltaic module on the transmission path of the discharging conveying unit, which can be the length of the photovoltaic module (when the photovoltaic module is transmitted along its length direction) or the width of the photovoltaic module (when the photovoltaic module is transmitted along its width direction).

[0031] The discharge conveyor unit 3 has a feed end 3a and a discharge end 3b. After the lamination process, the photovoltaic modules are transported from the feed end 3a to the discharge end 3b of the discharge conveyor unit 3. As a preferred embodiment, a first sensor 4 and a second sensor 5 are respectively provided near the feed end 3a and the discharge end 3b of the discharge conveyor unit 3.

[0032] The first sensor 4 and the second sensor 5 can be infrared sensors, visual recognition devices, pressure sensors, or position sensors. The first sensor 4 and the second sensor 5 can be provided in pairs, with the number of sensors being sufficient to accurately identify the number of photovoltaic modules. In this embodiment, the first sensor 4 and the second sensor 5 are both infrared sensors.

[0033] During the lamination process, the first sensor 4 and the second sensor 5 respectively detect the number of photovoltaic modules 101 passing through their positions, record them as values N1 and N2, and transmit the values to the control unit, which compares N1 and N2:

[0034] When N1=N2, the laminating device is operating normally and there is no component accumulation in the discharge conveyor unit 3. At this time, the control unit issues a control instruction, the laminating device operates normally, and the components are laminated in the laminating unit for the set first time T1. When N1>N2, it indicates that there is an operation failure of the laminating device and there is component accumulation in the discharge conveyor unit 3. At this time, the control unit issues a control instruction to extend the laminating time of the laminating unit for a second time T2, and the components are continuously laminated. N1 and N2 are both positive integers greater than 1.

[0035] Specifically, the first time T1 and the second time T2 can be set accordingly based on the specific component. For example, the first time T1 can be 1000 seconds and the second time T2 can be 120 seconds. In some extreme cases, after the second time T2 expires, if the detected status is still N1>N2, a new control instruction is issued to further extend the lamination time until the detected status is N1=N2, at which point the lamination device will operate normally.

[0036] Example 2:

[0037] This embodiment provides a lamination method, wherein a plurality of solar cells are laminated to form a photovoltaic module using a lamination device. The lamination device includes a feed conveying unit, a lamination unit, a discharge conveying unit, and a control unit. A first sensor and a second sensor are respectively provided on the discharge conveying unit at a distance of M photovoltaic modules, where M ≥ 1. The lamination method includes the following steps:

[0038] S1: The first sensor and the second sensor respectively detect the number of components passing through their positions, record them as N1 and N2 respectively, and upload the values N1 and N2 to the control unit in real time.

[0039] S2: The control unit compares the sizes of N1 and N2. When N1=N2, a control instruction is issued, the lamination device operates normally, and the component is laminated in the lamination unit for the first set time T1; when N1>N2, a control instruction is issued to make the lamination unit extend the lamination time, and the extended time lasts for the second time T2, and the component is continuously laminated.

[0040] Specifically, the first time T1 and the second time T2 can be set accordingly based on the specific component. For example, the first time T1 can be 900 seconds and the second time T2 can be 100 seconds. In some extreme cases, after the second time T2 expires, if the detected status is still N1>N2, a new control instruction is issued to further extend the lamination time until the detected status is N1=N2, at which point the lamination device will operate normally.

[0041] The first sensor and the second sensor can be an infrared sensor, a visual recognition device, a pressure sensor or a position sensor. N1 and N2 are both positive integers greater than 1.

[0042] In this embodiment, both the first sensor 4 and the second sensor 5 are pressure sensors.

[0043] As a preferred embodiment, the first sensor and the second sensor are respectively located at the feed end and the discharge end of the discharge conveying unit. Figure 1 As stated.

[0044] The specific embodiments described herein are merely examples of the spirit of the present invention. Those skilled in the art may make various modifications or additions to the specific embodiments described, or replace them with similar methods without departing from the spirit of the present invention.

Claims

1. A laminating device, characterized in that include: A feeding conveying unit, a laminating unit, a discharging conveying unit and a control unit. A first sensor and a second sensor are respectively arranged on the discharging conveying unit at a distance of M photovoltaic modules, M≥1. The first sensor and the second sensor can detect the number N1 and N2 of modules passing through their positions and transmit the values to the control unit. The control unit compares N1 and N2. When N1>N2, a control instruction is issued to make the laminating unit extend the lamination time and continuously laminate the modules. The first sensor and the second sensor are infrared sensors, visual recognition devices, pressure sensors or position sensors. The first sensor and the second sensor are respectively located at the feeding end and the discharging end of the discharging conveying unit.

2. The laminating device according to claim 1, characterized in that: Said M≥2.

3. The laminating device according to claim 1, characterized in that: The laminating unit is a laminator.

4. A lamination method, wherein a plurality of solar cells are laminated to form a photovoltaic module by a lamination device, characterized in that: The laminating device includes a feeding conveying unit, a laminating unit, a discharging conveying unit, and a control unit. A first sensor and a second sensor are respectively provided on the discharging conveying unit at a distance of M photovoltaic modules, where M is greater than or equal to 1. The laminating method includes the following steps: S1: The first sensor and the second sensor respectively detect the number of components passing through their positions, record them as N1 and N2 respectively, and upload the values N1 and N2 to the control unit in real time. S2: The control unit compares the sizes of N1 and N2. When N1=N2, a control instruction is issued, the lamination device operates normally, and the component is laminated in the lamination unit for the first set time T1; when N1>N2, a control instruction is issued to make the lamination unit extend the lamination time, and the extended time lasts for the second time T2, and the component is continuously laminated.

5. The lamination method according to claim 4, wherein: The first sensor and the second sensor are infrared sensors, visual recognition devices, pressure sensors or position sensors.

6. The lamination method according to claim 4, wherein: Said M≥2.

7. The lamination method according to claim 6, wherein: The first sensor and the second sensor are respectively located at the feed end and the discharge end of the discharge conveying unit.

8. The lamination method according to claim 4, wherein: The laminating unit is a laminator.

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