Low shrinkage photovoltaic film forming device

Abstract

The present invention relates to the technical field of photovoltaic film production, and specifically to a molding device for low-shrinkage photovoltaic films, including: a conveying stand, a molding and cutting mechanism, a molding support mechanism, and a stress relief box. The conveying stand is the main structure of the equipment, and a discharge roller frame located at one end of its top surface is fixedly installed on its surface for installing film rolls, and a tension adjustment component for adjusting the tension of the film material. The discharge roller frame is a replaceable reel structure, which is convenient for the installation and replacement of film materials, ensuring that the film rolls can be replaced quickly and conveniently during the production process to meet different production needs. In the present invention, multiple functions such as automatic conveying, slitting, high-temperature softening, and cooling and molding are integrated, which significantly improves the production efficiency of photovoltaic films. Through automated control, human intervention and operational errors are reduced, production costs are reduced, and at the same time, the consistency and stability of production are ensured.

Description

Technical Field

[0001] The invention relates to the technical field of photovoltaic adhesive film production, in particular to a molding device for low-shrinkage photovoltaic adhesive films. Background Art

[0002] With the rapid development of photovoltaic technology, photovoltaic films are increasingly used in photovoltaic modules, and their quality and production efficiency directly affect the performance and market competitiveness of photovoltaic products. The traditional photovoltaic film production process usually relies on manual operation, which is complicated, has low production efficiency, and is prone to operational errors, resulting in unstable film quality and molding defects. In addition, during the transportation and molding process of the film material, the lamination effect of the final product is often affected by uneven tension or position offset, which to a certain extent limits the further application of photovoltaic films.

[0003] In order to improve the production efficiency and molding quality of photovoltaic adhesive films, the industry has begun to seek automated and intelligent production solutions. The use of electrostatic adsorption technology can effectively solve the positioning problem of film materials during transportation, and use the electrostatic effect to firmly adsorb the film materials on the conveyor belt, thereby avoiding the risk of stretching and deviation. However, the real-time monitoring of the film material status in the existing technology is still insufficient, lacking an effective feedback mechanism, and it is difficult to achieve precise control.

[0004] Therefore, there is an urgent need for an integrated photovoltaic film forming device that can improve production efficiency, ensure forming quality, and reduce the risks of manual intervention and operational errors through advanced technologies such as automated control, electrostatic conveying, and real-time monitoring. This will not only help reduce production costs, but also help improve the market competitiveness of photovoltaic products and promote the sustainable development of the photovoltaic industry. Summary of the invention

[0005] The present invention aims to solve one of the technical problems existing in the prior art or related technology.

[0006] To this end, the technical solution adopted by the present invention is: a molding device for low-shrinkage photovoltaic adhesive film, including: a conveying stand, a molding and cutting mechanism, a shaping support mechanism and a stress relief box; the surface of the conveying stand is fixedly installed with a discharge roller frame located at one end of its top surface for installing a film roll, and a tension adjustment component for adjusting the tension of the film; the molding and cutting mechanism is fixed to the top surface of the conveying stand, including a film conveying table, an ion generator and a cutting component, one end of the film conveying table is rotatably installed with a transmission roller, and the ion generator is fixed to the inner side of the film conveying table and close to one end of the transmission roller, and the surface of the film conveying table is rotatably sleeved with a conveyor belt; the shaping support mechanism is located on the inner side of the conveying stand, and includes a lifting platform and a cooling system. Control box, the lifting platform includes a lifting frame, a driving motor, a feeding support bar and a transmission gear rod, the cooling control box, the driving motor and the feeding support bar are fixedly installed on the top of the lifting frame, the surface of the feeding support bar is provided with a conveying component for conveying the photovoltaic film molding substrate, and the input end of the feeding support bar is transmission-connected to the output end of the driving motor, the output end of the driving motor is provided with a transmission gear rod, the ends of the transmission roller and the transmission gear rod are provided with transmission teeth, the cooling control box is used for cooling the molding substrate on the surface of the feeding support bar, and by integrating the functions of automatic conveying, slitting, high temperature softening and cooling shaping, the production efficiency of the photovoltaic film is significantly improved, the manual intervention and operating errors are reduced, and the consistency and stability of the production are ensured.

[0007] In a preferred example, the present invention can be further configured as follows: the ion generator emits ions with different positive and negative charges on both sides to produce an electrostatic effect on the bottom and surface of the film material conveying platform, thereby electrostatically adsorbing the film material conveyed by the conveyor belt; when the film material passes over the ion generator, the electrostatic adsorption effect is lost, which facilitates the separation of the film material from the surface of the conveyor belt, and when the conveyor belt moves to the bottom of the ion generator, the charge that can be electrostatically adsorbed is re-carried. The electrostatic adsorption technology ensures the precise positioning of the film material during the conveying process and prevents stretching and deviation, thereby optimizing the fitting effect of the film material and avoiding molding defects.

[0008] In a preferred example, the present invention can be further configured as follows: the surfaces of the transmission roller and the transmission gear rod are sleeved with transmission teeth that transmit each other, and the transmission tooth diameter of the transmission gear rod is smaller than the transmission tooth diameter at the end of the transmission roller, which is used to generate a transmission ratio between the transmission gear rod and the transmission roller. The optimized transmission design improves the power transmission efficiency, ensures the coordinated operation of various components of the equipment, and improves the overall working efficiency.

[0009] In a preferred example, the present invention can be further configured as follows: the unwinding roller frame is a replaceable reel structure, which is convenient for the installation and replacement of the film material, and the tension adjustment component is an electric tension adjustment device for accurately adjusting the tension of the film material to ensure stability during the conveying process. The application of the electric tension adjustment device ensures that the film material maintains a constant tension during the entire conveying process, avoiding damage or deformation of the film material due to uneven tension.

[0010] In a preferred example, the present invention can be further configured as follows: the temperature control box is one of air cooling or spray water cooling, which can effectively reduce the substrate temperature and improve the bonding quality between the film material and the substrate. The rapid cooling mechanism ensures that the film material solidifies quickly after bonding, thereby improving the molding quality and production efficiency.

[0011] In a preferred example, the present invention can be further configured as follows: the heating and softening device of the stress relief box is a multi-stage heating structure, which realizes uniform heating of the film material by controlling different temperature sections, thereby ensuring the best performance of the film material during the molding process. The uniform heating process avoids local overheating or underheating, thereby improving the consistency and quality of the final product.

[0012] In a preferred example, the present invention can be further configured as follows: the horizontal height of the feed support bar is lower than the conveying frame in the initial state, and the horizontal height of the feed support bar is higher than the conveying frame after the lifting frame is lifted, so that the substrate can be smoothly bonded with the film material and the stability of the bonding process is guaranteed, thereby ensuring the effective bonding of the substrate and the film material and avoiding unstable factors during the molding process.

[0013] In a preferred example, the present invention can be further configured as follows: the input ends of the ion generator, feed support bar, tension adjustment component and cutting component are electrically connected to a control system; a film material sensor close to a section of the tension adjustment component is fixedly installed on the surface of the film material conveying table, which is used to monitor the state of the film material in real time and feed back to the control system; a number of temperature sensors are provided on the inner sides of the stress relief box and the temperature reduction control box, which are used to monitor the temperature of the film material and the substrate and adjust them to ensure uniform heating of the film material and rapid cooling of the substrate, thereby achieving stable conveying and efficient molding of the film material. The real-time monitoring mechanism improves the intelligence level of the equipment, ensures stability and reliability in the production process, and optimizes production efficiency.

[0014] The beneficial effects achieved by the present invention are:

[0015] 1. The present invention integrates multiple functions such as automatic conveying, slitting, high temperature softening and cooling shaping, which significantly improves the production efficiency of photovoltaic adhesive film. Through automatic control, manual intervention and operational errors are reduced, production costs are reduced, and the consistency and stability of production are ensured.

[0016] 2. In the present invention, the electrostatic adsorption conveying technology is used to effectively and precisely position the film material and prevent stretching deviation during the conveying process. This technology uses the electrostatic effect generated by the ion generator to firmly adsorb the film material on the surface of the conveyor belt, ensuring that the film material is always in the best position during the molding process. At the same time, through the differential transmission design, the tension stretching of the film material is achieved, the lamination effect of the film material is optimized, and molding defects caused by position deviation are avoided.

[0017] 3. In the present invention, sensors for real-time monitoring of the film material status are installed at key locations, which can timely feed back information such as the film material thickness, tension and temperature to the control system. This mechanism enhances the intelligence level of the equipment, enables the control system to automatically adjust the working parameters according to real-time data, and improves the stability and reliability of the production process. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 It is a schematic diagram of the overall structure of an embodiment of the present invention;

[0019] Figure 2 It is a schematic diagram of the structure of a conveying stand, a forming and cutting mechanism and a shaping support mechanism according to an embodiment of the present invention;

[0020] Figure 3 For an embodiment of the present invention Figure 2 A schematic diagram of the structure at A;

[0021] Figure 4 It is a schematic diagram of the structure of a film material conveying platform and a lifting platform according to an embodiment of the present invention;

[0022] Figure 5 This is a schematic diagram of the structure of a forming and cutting mechanism according to an embodiment of the present invention;

[0023] Figure 6 For an embodiment of the present invention Figure 5 Schematic diagram of the structure at B;

[0024] Figure 7 This is a schematic diagram of the structure of a transmission roller and an ion generator according to an embodiment of the present invention;

[0025] Figure 8 The figure is a schematic diagram of the structure of a lifting platform according to an embodiment of the present invention.

[0026] Reference numerals:

[0027] 100, conveying stand; 110, unwinding roller stand; 120, tension adjustment assembly;

[0028] 200, forming and cutting mechanism; 210, film material conveying platform; 220, ion generator; 230, cutting assembly; 211, transmission roller; 212, conveyor belt; 231, lifting and lowering adjustment rod; 232, driving rail; 233, cutting seat;

[0029] 300, forming support platform mechanism; 310, lifting platform; 320, temperature control box; 311, lifting frame; 312, driving motor; 313, feeding support bar; 314, transmission gear rod;

[0030] 400. Stress relief box. DETAILED DESCRIPTION

[0031] To make the purpose, technical solution and advantages of the present invention more clear, the present invention is further described in detail below in combination with specific implementations and with reference to the accompanying drawings. It should be noted that the embodiments of the present invention and the features in the embodiments can be combined with each other without conflict.

[0032] It is to be understood that these descriptions are exemplary only and are not intended to limit the scope of the invention.

[0033] The following describes a molding device for a low-shrinkage photovoltaic adhesive film provided by some embodiments of the present invention in conjunction with the accompanying drawings.

[0034] Combination Figure 1-Figure 7 As shown, the molding device of the low shrinkage photovoltaic adhesive film provided by the present invention includes: a conveying stand 100, a molding and cutting mechanism 200, a molding support mechanism 300 and a stress relief box 400. The conveying stand 100 is the main structure of the equipment, and a discharge roller frame 110 located at one end of its top surface is fixedly installed on its surface for installing the film roll, and a tension adjustment component 120 for adjusting the tension of the film material. The discharge roller frame 110 is a replaceable reel structure, which is convenient for the installation and replacement of the film material, ensuring that the film roll can be replaced quickly and conveniently during the production process to meet different production needs. The tension adjustment component 120 is an electric tension adjustment device that can accurately adjust the tension of the film material to ensure stability during the transportation process and avoid damage or deformation of the film material due to uneven tension.

[0035] The molding and cutting mechanism 200 is fixed on the top surface of the conveying platform 100, and includes a film material conveying platform 210, an ion generator 220 and a cutting assembly 230. A driving roller 211 is rotatably mounted on one end of the film material conveying platform 210, and the ion generator 220 is fixed on the inner side of the film material conveying platform 210 and close to one end of the driving roller 211, and a conveyor belt 212 is rotatably sleeved on the surface of the film material conveying platform 210. The ion generator 220 generates an electrostatic effect on the bottom and surface of the film material conveying platform 210 by emitting ions with different positive and negative charges on both sides, thereby electrostatically adsorbing the film material conveyed by the conveyor belt; when the film material passes above the ion generator 220, the electrostatic adsorption effect is lost, which facilitates the film material to separate from the surface of the conveyor belt 212, and when the conveyor belt 212 moves to the bottom of the ion generator 220, it is charged again for electrostatic adsorption. Specifically, the ion generator 220 emits ions of different positive and negative charges on both sides, so that the conveyor belt 212 generates an electrostatic effect on the surface after it moves to the bottom surface of the film material conveying platform 210 and below the cutting assembly 230. After passing above the ion generator 220, the oppositely charged ions eliminate the electrostatic effect, so that the film loses the electrostatic adsorption effect and is easy to separate from the surface of the conveyor belt 212. This electrostatic adsorption technology ensures the precise positioning of the film material during the conveying process, prevents stretching and deviation, thereby optimizing the lamination effect of the film material and avoiding molding defects.

[0036] The shaping support mechanism 300 is located inside the conveying platform 100, and includes a lifting platform 310 and a temperature control box 320. The lifting platform 310 includes a lifting frame 311, a drive motor 312, a feed support bar 313 and a transmission gear rod 314. The temperature control box 320, the drive motor 312 and the feed support bar 313 are fixedly installed on the top of the lifting frame 311. The surface of the feed support bar 313 is provided with a conveying assembly for conveying the photovoltaic film forming substrate, and the input end of the feed support bar 313 is transmission-connected to the output end of the drive motor 312, and the output end of the drive motor 312 is provided with a transmission gear rod 314. The ends of the transmission roller 211 and the transmission gear rod 314 are both provided with transmission teeth, wherein the surfaces of the transmission roller 211 and the transmission gear rod 314 are sleeved with transmission teeth that transmit each other, and the transmission teeth diameter of the transmission gear rod 314 is smaller than the transmission teeth diameter at the end of the transmission roller 211, which is used to generate a transmission ratio between the transmission gear rod 314 and the transmission roller 211. This optimized transmission design improves the power transmission efficiency, ensures the coordinated operation of various components of the equipment, and improves the overall work efficiency.

[0037] The temperature control box 320 is used to cool the molding substrate on the surface of the feeding support bar 313, specifically one of air cooling or spray water cooling, which can effectively reduce the substrate temperature and improve the bonding quality between the film material and the substrate. The stress relief box 400 is fixed to the top surface of the molding and cutting mechanism 200 and is used for heating and softening the film material, wherein the heating and softening device of the stress relief box 400 is a multi-stage heating structure, which realizes uniform heating of the film material by controlling different temperature sections, ensuring the best performance of the film material during the molding process. The uniform heating process avoids local overheating or underheating, and improves the consistency and quality of the final product.

[0038] In this embodiment, the horizontal height of the feed support bar 313 is lower than the conveying platform 100 in the initial state, and the horizontal height of the feed support bar 313 is higher than the conveying platform 100 after the lifting frame 311 is lifted, so that the substrate can be smoothly bonded with the film material and the stability during the bonding process is ensured. In addition, the input ends of the ion generator 220, the feed support bar 313, the tension adjustment component 120 and the cutting component 230 are electrically connected to the control system; the surface of the film material conveying platform 210 is fixedly installed with a film material sensor close to the tension adjustment component 120, which is used to monitor the state of the film material in real time and feed back to the control system; the inner side of the stress relief box 400 and the temperature control box 320 is provided with a plurality of temperature sensors, which are used to monitor the temperature of the film material and the substrate and adjust it to ensure uniform heating of the film material and rapid cooling of the substrate, thereby realizing stable transportation and efficient molding of the film material. The real-time monitoring mechanism improves the intelligence level of the equipment, ensures the stability and reliability during the production process, and optimizes the production efficiency.

[0039] The specific implementation of the present invention realizes the efficient molding of low-shrinkage photovoltaic adhesive film through the synergistic effect of the above-mentioned various components, and has significant economic benefits and application prospects.

[0040] The working principle and use process of the present invention:

[0041] The photovoltaic film material roller is arranged on the surface of the unwinding roller frame 110 and pulls one end of the film material through the tension adjustment component 120 and the gap between the film material conveying platform 210 and the cutting component 230. The film material is attached to the surface of the conveyor belt 212 and moves along with the conveyor belt 212 through the electrostatic effect between the surface of the conveyor belt 212 and the film material. The movement of the lifting adjustment rod 231 is adjusted as much as possible according to the thickness of the film material to avoid damage to the surface of the conveyor belt 212 during the downward cutting of the film material by the cutting knife seat 233. The driving motor 312 is connected to the transmission gear rod 314 through the transmission gear rod 314. The transmission of the driving roller 211 drives the conveyor belt 212 to circulate on the surface of the film material conveying platform 210 to convey the film material; when the film material passes through the cutting component 230 and moves to a certain length, the control system automatically stops the film material conveying platform 210, and the lifting and lowering adjustment rod 231 controls the driving rail 232 and the cutting seat 233 to move downward and protrude from the surface of the film material. During the linear sliding process of the cutting seat 233 along the surface of the driving rail 232, the film material is cut by the cutting seat 233, and the cut film material is evenly heated by the heating lamp inside the stress relief box 400;

[0042] Synchronously, the surface of the conveying platform 100 conveys the molding substrate inputted into one end of the molding cutting mechanism 200, until one end of the substrate moves to the bottom of the driving roller 211, and the control system automatically controls the driving roller 211 to rise, so that the substrate is separated from the active conveying of the conveying platform 100, and the surface conveying member of the feeding support bar 313 is used to push and convey the substrate, so that it passes under the driving roller 211 at a uniform speed, and synchronously reaches the surface of the conveyor belt 212. The film material is attached to the surface of the substrate under the rolling pressure of the conveyor belt 212 and the driving roller 211, and the surface energy of the metal substrate and the film material and the electrostatic effect make the film material adhere to the surface of the substrate, and as the substrate, the driving roller 211 and the conveyor belt 212 convey the film material, the film material is evenly fixed on the surface of the substrate;

[0043] The ion generator 220 emits ions of different positive and negative charges on both sides, so that the conveyor belt 212 generates an electrostatic effect on the surface when it moves to the bottom surface of the film material conveying platform 210 and below the cutting assembly 230. After passing above the ion generator 220, the oppositely charged ions eliminate the electrostatic effect, so that the film material loses the electrostatic adsorption effect and is easy to separate from the surface of the conveyor belt 212.

[0044] During the bonding process, due to the relationship between the gear ratio of the transmission gear rod 314 and the end of the transmission roller 211, the speed of the conveyor belt 212 conveying the film material is slightly lower than the conveying rate of the feed support strip 313 to the substrate. The film material heated and softened in the stress relief box 400 is subjected to a certain tension and stretching effect during the bonding process with the substrate. On the one hand, the film material is kept in an extended state, and on the other hand, the film material is stretched; under the action of the temperature reduction control box 320 on the metal substrate, the surface temperature of the substrate is reduced, and the low-temperature substrate allows the film material attached to the surface of the substrate to quickly conduct and cool down, and the stretched film material is cooled and shaped; the conveyor belt 212 regenerates the electrostatic adsorption effect on the lower surface under the action of the ions sprayed from the lower part of the ion generator 220, and circulates to the top of the film material conveying platform 210, and circulates to carry out the conveying and shaping work of the next section of the film material, and the lifting stand 311 descends to make the feed support strip 313 disappear under the conveying platform 100 to wait for the next substrate to be received.

[0045] In the description of this specification, the description of the terms "one embodiment", "some embodiments", "specific embodiments", etc. means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representation of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner.

[0046] Although the embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the claims and their equivalents.

Claims

1. A molding device for low shrinkage photovoltaic film, characterized in that: include: Conveying platform, forming and cutting mechanism, shaping support mechanism and stress relief box; The surface of the conveying platform is fixedly mounted with a discharge roller frame located at one end of the top surface thereof for mounting the film material roll, and a tension adjustment component for adjusting the tension of the film material; The molding and cutting mechanism is fixed to the top surface of the conveying platform; the molding and cutting mechanism includes a film material conveying platform, an ion generator and a cutting assembly, one end of the film material conveying platform is rotatably mounted with a transmission roller, and the ion generator is fixed to the inner side of the film material conveying platform and close to one end of the transmission roller, and the surface of the film material conveying platform is rotatably sleeved with a conveyor belt; The shaping support mechanism is located on the inner side of the conveying platform, and includes a lifting platform and a temperature-lowering control box. The lifting platform includes a lifting frame, a driving motor, a feeding support bar and a transmission gear rod. The temperature-lowering control box, the driving motor and the feeding support bar are fixedly installed on the top of the lifting frame. The surface of the feeding support bar is provided with a conveying assembly for conveying the photovoltaic film forming substrate, and the input end of the feeding support bar is transmission-connected with the output end of the driving motor. The output end of the driving motor is provided with a transmission gear rod. The temperature-lowering control box is used to cool the substrate formed on the surface of the feeding support bar; the surfaces of the transmission roller and the transmission gear rod are sleeved with transmission teeth that transmit each other. The transmission tooth diameter of the transmission gear rod is smaller than the transmission tooth diameter at the end of the transmission roller, and is used to generate a transmission ratio between the transmission gear rod and the transmission roller; The stress relief box is fixed to the top surface of the molding and cutting mechanism and is used for heating and softening the film material.

2. The low shrinkage photovoltaic film forming device according to claim 1, characterized in that: The ion generator emits ions with different positive and negative charges on both sides, generating an electrostatic effect on the bottom and surface of the film material conveying platform, thereby electrostatically adsorbing the film material conveyed by the conveyor belt; when the film material passes over the ion generator, it loses the electrostatic adsorption effect, making it easier for the film material to separate from the conveyor belt surface, and when the conveyor belt moves to the bottom of the ion generator, it is re-charged with charges that can perform electrostatic adsorption.

3. The low shrinkage photovoltaic film forming device according to claim 1, characterized in that: The unwinding roller frame is a replaceable reel structure, and the tension adjustment component is an electric tension adjustment device for accurately adjusting the tension of the film material.

4. The low shrinkage photovoltaic film forming device according to claim 1, characterized in that: The temperature-lowering control box is one of air cooling and spray water cooling.

5. The low shrinkage photovoltaic film forming device according to claim 1, characterized in that: The heating and softening device of the stress relief box is a multi-stage heating structure.

6. The low shrinkage photovoltaic film forming device according to claim 1, characterized in that: The horizontal height of the feeding support bar is lower than the conveying platform in the initial state, and the horizontal height of the feeding support bar is higher than the conveying platform after the lifting frame is lifted, so that the substrate can be smoothly bonded with the film material and the stability during the bonding process is guaranteed.

7. The low shrinkage photovoltaic film forming device according to claim 2, characterized in that: The input ends of the ion generator, feeding support bar, tension adjustment component and cutting component are electrically connected to a control system; a film material sensor close to the tension adjustment component is fixedly installed on the surface of the film material conveying table for real-time monitoring of the film material status and feeding back to the control system.

8. The low shrinkage photovoltaic film forming device according to claim 1, characterized in that: A number of temperature sensors are provided inside the stress relief box and the temperature control box for monitoring and adjusting the temperature of the film material and the substrate to ensure uniform heating of the film material and rapid cooling of the substrate, thereby achieving stable conveying and efficient molding of the film material.

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