Laminating machine device and method for manufacturing curved laminated solar panel

Abstract

Apparatus, systems, and methods of a laminating machine capable of producing hyperboloid solar panels having hyperboloid solar cells are disclosed. The laminator panel includes a housing divided by a film into a lower chamber and an upper chamber, the lower housing including a convex surface in the form of a mold and / or tray having a desired panel shape. The convex surface has a shape that causes gentle bending in the film at the edge of the panel under lamination conditions. The tray may include an aperture at an edge of the panel for venting encapsulant vapor, while the mold includes a channel in communication with the vacuum for collecting the vapor. The housing is configured to prevent excessive extension of the membrane. The lift pin provides thermal insulation from the convex surface. A lamination method is provided in which a laminate stack can be secured to itself and to a convex surface using a removable tape.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to and the benefit of co-pending U.S. Provisional Patent Application No. 63 / 321,627, filed on March 18, 2022, entitled “Laminator Apparatus And Method Of Making CurvedLaminated Solar Panel,” the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present invention generally relates to a laminator apparatus for making multi-dimensional laminated products. In particular, the present invention relates to an apparatus, system and method for making laminated solar panel products having a double axis of curvature. Background Art

[0004] In the solar electric vehicle sector, the use of solar panels presents challenges because the desired body design often includes complex geometries, such as surfaces on the roof, hood, or trunk. The manufacture of solar panels with complex geometries is challenging for a variety of reasons. The main cause of failure during the manufacturing process (especially during lamination) is stresses caused by simple or complex bending, torsion, or other deformations that exceed the ultimate strength of the semiconductor material. For example, forced deformation of silicon cells into the same direction of the panel surface can cause particularly high internal stresses, which can lead to brittle fracture or premature failure. For these and other reasons, it is difficult to achieve low failure rates when laminating solar cells into complex panel shapes, and it is difficult to do so in a large-volume, high-yield manner.

[0005] Despite strong incentives across industries, there remains a long-felt need for a laminator for manufacturing hyperbolic solar panels with hyperbolic solar cells.

[0006] Laminators capable of producing curved panels share common elements with flat-panel laminators, including features that provide heat, vacuum, and pressure. It is particularly important to apply uniform pressure, for which a deformable elastic membrane is typically used. For curved laminators, a device or method for imparting or maintaining a precise shape is also necessary. To this end, a curved mold or a thin curved plate or both are typically used. However, problems arise when the elastic membrane is stretched over the surface of a curved panel. When the deformation of the membrane is large at the edge of the panel and the thickness of the panel is not negligible, the sharp change in the direction of the membrane can lead to localized uneven pressure and panel failure. Such panel deformation can lead to incomplete venting, bubble formation, improper curing, edge delamination, and panel failure. Therefore, it is very important to control the direction of the membrane at the edge of the panel to prevent uneven pressure areas.

[0007] In a similar problem, film-based laminators are susceptible to film failure during multiple lamination cycles where the film is forced into sharp corners or edges of the lamination chamber. When conforming to these features, the film overstretches and can develop cracks and tears.

[0008] To reduce the lamination cycle time in a die-based laminator, the die is kept at lamination temperature, thereby avoiding extended heat ramp times and improving energy efficiency. However, laying down the laminate material on such a heated surface would be extremely challenging. Therefore, it is desirable to prepare the laminate stack individually and load it into the chamber as a unit. Furthermore, to allow a vacuum to be established in the lower chamber, it is desirable to keep the laminate stack a short distance from the die, thereby keeping it at a controlled temperature before lowering it onto the die. This is typically achieved by lift pins embedded in the die. However, these pins are typically made of stainless steel, aluminum or other metals and are thermally conductive. As a result, the temperature of the laminate stack areas close to the lift pins may be slightly higher than the surrounding layers and begin to cure prematurely. This can result in uneven curing of the panel.

[0009] During the lamination process, the encapsulation or "glue" layer often contains volatiles that must be expelled from the film in order for the layer to cure. The entrapment of volatile components can lead to bubble formation, incomplete cure, delamination, and panel failure. The primary cause of trapped gas is that the film seals the panel edge to the mold, preventing the gas from escaping from the vacuum side of the laminator.

[0010] During the lamination process, the temperature of the tray must be uniform and controllable during the curing phase. For laminators that use both trays and molds, the primary method of heating the tray is by conduction through the mold. Therefore, uniform physical contact between the tray and the mold is critical. However, the tray and laminate stack are loaded into the laminator at ambient temperature, while the mold is maintained at a higher temperature. Therefore, if the dimensions of the tray match the mold at ambient temperature, the tray will necessarily be small relative to the mold when loaded into the mold. In addition, if the geometry of the tray and mold includes a relative vertical interface, the tray will not be able to load into the mold before reaching the mold temperature. If the tray is located above the mold, it may take too long to heat only by convection and / or radiation. A better system is needed.

[0011] Automotive body panels are manufactured to tolerances of about ±1 mm. The same tolerances must be met for solar body panels, which contain a variety of metallic and non-metallic materials. The heterogeneity of solar panels makes this a challenge for a variety of reasons. First, solar panels are not monolithic sheets of metal, but are made by joining together multiple layers of different materials and materials of different sizes. This, in turn, requires that they be aligned with each other so that there is a single, uniform edge so that the protective edge can be assembled to it, so that it mates with the frame correctly, so that the electrical feedthroughs can be filled with short conductors, so that the printed pattern does not cover the solar cells, and so on. Therefore, a robust alignment system and method is needed to achieve manufacturability. The system and / or method may be different for low-volume production and high-volume production.

[0012] Complicating solar body panel manufacturing is the thermal profile of the lamination process. Due to the large differences in the coefficients of thermal expansion (CTE) of the materials involved, the laminate stack will expand or contract relative to the tray or mold. For example, polymer materials will expand relative to the aluminum tray, while glass materials will contract when the temperature increases. In addition, pressure applied through the film may cause the superstrate to translate relative to the substrate, resulting in misalignment. For these reasons, a robust alignment maintenance scheme is required to ensure manufacturability of production. The system and / or method may be different for low-volume production and high-volume production. Summary of the invention

[0013] The present invention solves the above-mentioned defects by providing a laminator device, system and method for manufacturing hyperbolic solar panels with hyperbolic solar cells, and the laminator is capable of continuous output. In one embodiment, the laminator includes a clamshell laminator device, system and lamination method. In another embodiment, the laminator includes a vertical upward stamping device, system and lamination method. Unless otherwise stated, the contents of the present invention and the concepts described herein are applicable to any type of laminator, whether a clamshell laminator or a vertical upward stamping laminator.

[0014] It is an object of the present invention to provide a mold and / or tray design that minimizes pressure non-uniformity caused by film bending at the edges of curved panels.

[0015] It is an object of the present invention to provide a method of preventing premature failure of the film due to excessive extension into the sharp corners and edges of the lamination chamber.

[0016] It is an object of the present invention to provide a method for reducing heat conduction between lift pins and a heated lamination stack in a die-based laminator to ensure a more spatially uniform cure.

[0017] It is an object of the present invention to provide a method for venting gases that would otherwise be trapped by the film as it seals the panel to the tray and / or mold.

[0018] It is an object of the present invention to provide a method of maintaining alignment and uniform thermal contact between a tray and a mold during elevated tray temperatures.

[0019] It is an object of the present invention to provide a robust system and method for laminate stack alignment.

[0020] It is an object of the present disclosure to provide a robust system and method for maintaining alignment of a lamination stack and a tool during the lamination process.

[0021] Other desirable features and characteristics will become apparent from the subsequent detailed description, drawings, and appended claims, when considering this abstract. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Non-limiting and non-exhaustive embodiments of the present invention are described with reference to the following drawings.In the drawings, like reference numerals describe like components throughout the several views.

[0023] For a better understanding of the present invention, reference will be made to the following detailed description, which should be read in conjunction with the accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate certain aspects of the subject matter disclosed herein, and together with the description help explain some principles associated with the disclosed embodiments, in which:

[0024] Figure 1A A perspective view of a hyperbolic solar panel including hyperbolic solar cells according to an embodiment of the present invention is shown;

[0025] Figure 1B The embodiment according to the present invention is shown Figure 1A A magnified view of

[0026] Figure 2A A perspective view of a flanged hyperbolic solar panel including hyperbolic solar cells is shown according to an embodiment of the present invention;

[0027] Figure 2B The embodiment according to the present invention is shown Figure 2A A cross-sectional view of

[0028] Figure 2C The embodiment according to the present invention is shown Figure 2B Detailed view of

[0029] Figure 3A A perspective view showing a vertical upstroke laminator according to an embodiment of the present invention;

[0030] Figure 3B A perspective view showing a clamshell laminator according to an alternative embodiment of the present invention;

[0031] Figure 4A A perspective view showing a mold with a heating element according to an embodiment of the present invention;

[0032] Figure 4B A perspective view showing an upper housing with a heating element according to an embodiment of the present invention;

[0033] Figure 5A A perspective view of an upper tray and a lower tray according to an embodiment of the present invention is shown, wherein a heating element is disposed on the upper tray;

[0034] Figure 5B The embodiment according to the present invention is shown Figure 5A A cross-sectional view of

[0035] Fig. 6A shows a cross-sectional view of a laminate stack with a temporary alignment adhesive according to an embodiment of the present invention;

[0036] Figure 6B shows a cross-sectional view of a laminator with thermally isolated lift pins in a load / unload configuration in accordance with an embodiment of the present invention;

[0037] Fig. 7A shows a cross-sectional view of an open laminator with an exploded view of a laminate stack and lift pins in a loading position according to an embodiment of the present invention;

[0038] Figure 7B shows a cross-sectional view of a closed laminator with a laminate stack in an evacuation and preheating configuration according to an embodiment of the present invention;

[0039] Figure 7C shows a cross-sectional view of a closed laminator with a lamination stack in a laminating configuration according to an embodiment of the present invention;

[0040] Fig.7D shows a cross-sectional view of an opened laminator with a laminate panel, a tray and lift pins in an unloading position according to an embodiment of the present invention;

[0041] Figure 8 Exemplary process steps involving a laminator capable of forming a laminated material into a hyperbolic solar panel according to an embodiment of the present invention are shown;

[0042] Fig.9A shows a cross-sectional view of a circular die and an unstressed membrane according to physics;

[0043] Fig. 9BA cross-sectional view of a circular die and a lightly compressed membrane is shown according to physics;

[0044] Fig. 9C A cross-sectional view of a circular die and a moderately compressed membrane is shown according to physics;

[0045] Fig.9D shows a cross-sectional view of a circular die and a heavily stressed membrane according to physics;

[0046] Fig. 10A A partial cross-sectional view of a circular die and a fully compressed membrane is shown according to physics;

[0047] Fig. 10B shows a partial cross-sectional view of a circular die with a laminated stack and a slightly compressed membrane according to physics;

[0048] Fig. 10C shows a partial cross-sectional view of a circular die with a laminated stack and a moderately compressed membrane according to physics;

[0049] Fig.11A showing a cross-sectional view of a mold having an obtuse angle at the edge of a solar panel and having a fully compressed film in accordance with an embodiment of the present invention;

[0050] Fig. 11B shows a cross-sectional view of a mold with a panel recess and a fully compressed membrane according to an embodiment of the present invention;

[0051] Fig. 11C shows a cross-sectional view of a tray with punched panel recesses, a die with matching machined recesses, and a fully compressed membrane in accordance with an embodiment of the present invention;

[0052] Fig.11D shows a cross-sectional view of a tray with a stamped panel riser, a smooth die, and a fully compressed membrane according to an embodiment of the present invention;

[0053] Fig.11E shows a cross-sectional view of a tray with assembled panel risers, smooth mold, and fully pressurized membrane according to an embodiment of the present invention;

[0054] Fig. 12A shows a cross-sectional view of a tray with vertical side walls at ambient temperature, a mold with vertical side walls at elevated temperature, and a fully compressed film according to an embodiment of the present invention;

[0055] Fig. 12B shows a cross-sectional view of a tray with vertical side walls, a mold with matching vertical side walls (all at elevated temperatures), and a fully compressed film according to an embodiment of the present invention;

[0056] Fig.13Ashows a cross-sectional view of a tray having a sloped sidewall at ambient temperature and a mold having a sloped sidewall at an elevated temperature according to an embodiment of the present invention;

[0057] Fig. 13B shows a cross-sectional view of a tray with a sloped sidewall and a mold with a sloped sidewall, both at elevated temperatures, according to an embodiment of the present invention;

[0058] Fig.14A shows a cross-sectional view of a tray having vertical sidewalls and compliant alignment features at ambient temperature and a mold having vertical sidewalls at elevated temperature in accordance with an embodiment of the present invention;

[0059] Fig. 14B shows a cross-sectional view of a tray with vertical sidewalls and compliant alignment features and a mold with vertical sidewalls, both at elevated temperatures, in accordance with an embodiment of the present invention;

[0060] Fig.15A shows a cross-sectional view of a laminator according to the prior art, wherein the film is pulled into a sharp-angled upper chamber by vacuum;

[0061] Fig. 15B shows a cross-sectional view of a laminator according to the prior art, wherein the film is pulled into a sharp-angled lower chamber by vacuum;

[0062] Fig.16A shows a cross-sectional view of a laminator according to an embodiment of the present invention, wherein the film is pulled into a rounded upper chamber by vacuum;

[0063] Fig. 16B shows a cross-sectional view of a laminator according to an embodiment of the present invention, wherein the film is pulled into a rounded lower chamber by vacuum;

[0064] Fig.17A shows a cross-sectional view of a laminator with a relaxed film placed in a mold according to an embodiment of the present invention;

[0065] Fig. 17B shows a cross-sectional view of a laminator according to an embodiment of the present invention, wherein a relaxed film is pulled into an upper chamber by a slight vacuum; and

[0066] Fig.18 A cross-sectional view of a tray with punched panel grooves and ventilation holes near the panel edge and a mold with ventilation channels according to an embodiment of the present invention is shown. DETAILED DESCRIPTION

[0067] Non-limiting embodiments of the present invention will be described below with reference to the accompanying drawings, wherein the same reference numerals represent the same elements throughout. Although the present invention has been described in detail with respect to preferred embodiments of the present invention, it should be understood that certain variations of the preferred embodiments will become apparent upon reading and understanding the foregoing, but these variations are still within the spirit and scope of the present invention. The accompanying drawings shown in the drawings are used to illustrate some embodiments of the present invention and should not be construed as limiting the present invention.

[0068] The terms "a" or "an", as used herein, are defined as one or more than one. The term "plurality", as used herein, is defined as two or more than two. The term "another", as used herein, is defined as at least a second or more. The terms "including" and / or "having", as used herein, are defined as comprising (i.e., open language). The term "coupled", as used herein, is defined as connected, although not necessarily directly and not necessarily mechanically.

[0069] References herein to "some embodiments," "one embodiment," "certain embodiments," and "embodiments," or similar terms mean that a particular feature, structure, or characteristic described in connection with that embodiment is included in at least one embodiment of the present invention. Thus, appearances of these phrases or occurrences of these phrases in various places throughout this specification do not necessarily all refer to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments without limitation.

[0070] As used herein, the term "or" should be interpreted as inclusive or meaning any one or any combination. Thus, "A, B, or C" means any of the following: "A; B; C; A and B; A and C; B and C; A, B, and C". An exception to this definition will only occur if the combination of elements, functions, steps, or actions is inherently mutually exclusive to some extent.

[0071] The drawings shown in the figures are used to illustrate some embodiments of the present invention and should not be considered as limiting the present invention. The term "mechanism" before the present participle of operation indicates a desired function, which has one or more embodiments, i.e., one or more methods, devices or apparatuses for realizing the desired function, and those skilled in the art can select from these embodiments or their equivalents according to the disclosure of this article, and the use of the term "mechanism" is not intended to be limiting.

[0072] Figure 1A and 1BThe exemplary laminated solar panel 100 shown in includes a solar cell array 200 encapsulated in multiple polymer layers. The solar panel can be bent about two axes x and y. The radius of curvature about each axis in one or more portions of the panel is such that the cells 210 of the solar cell array 200 must be bent in two directions. In addition, the panel 100 can be unevenly curved, for example, having a greater curvature in some portions relative to other portions. The hyperbolic laminated solar panel 100 can be manufactured according to the disclosure of co-pending patent application No. 18 / 169,576, filed on February 15, 2023, entitled “Curved Laminated Solar Panel and Method of Manufacturing,” which is incorporated herein by reference. In addition, according to the disclosure of co-pending patent application No. 18 / 168,274 filed on February 13, 2023, entitled "Plant Providing Continuous Process for Making Laminated Solar Panels", which is also incorporated herein by reference.

[0073] Figure 1BThe laminated structure shown in the detailed view of includes multiple polymer layers that are used for various purposes in the structure and function of the solar panel 100. The bottom is the substrate 120, which includes one or more polymer layers that provide mechanical rigidity and waterproof sealing. In this example, the substrate 120 includes an ethylene-tetrafluoroethylene copolymer (ETFE) flexible layer 126, a flexible adhesive layer 124, and a polycarbonate (PC) rigid layer 122. The top is a cover plate 130, which includes one or more polymer layers that provide mechanical rigidity, moisture-proof sealing, and resistance to impact damage. In this embodiment, the cover plate 130 includes a polycarbonate PC rigid layer 132, a flexible adhesive layer 134, and an ETFE flexible layer 136. Typically, polycarbonate (PC) 122, 132 can be configured to provide mechanical rigidity and impact resistance; while ethylene-tetrafluoroethylene copolymer (ETFE) 126, 136 acts as a waterproof barrier, reduces dirt accumulation and provides scratch resistance. At the center may be a core 110 comprising cells 210 of a solar cell array 200 surrounded by a layer of a flowing melt adhesive such as a polyolefin elastomer (POE) 112. The polyolefin elastomer (POE) 112 acts as a waterproof barrier and improves durability and reliability. In alternative embodiments, the substrate 120 and superstrate 130 may comprise a single layer of chemically or thermally strengthened glass. Lamination equipment capable of producing such a solar panel 100 would be advantageous.

[0074] In some applications, you can use Figure 2A and 2B A solar panel with flanges is shown and provides certain advantages. Figure 2A , the solar panel 100 includes a solar cell array 200 sandwiched between a substrate 120 and a cover plate 130, and also includes a frame ending at a flange 140. In this embodiment, as Figure 2B and 2C As shown in the cross-sectional and detailed views in FIG, the core 100 and substrate 120 are terminated at interface 141 by a cover flange 140. Thus, the core 110 and substrate 120 integrally form a seal against water ingress and delamination, although there may be some water vapor permeation through the PC 132. Therefore, a laminating apparatus capable of producing such a flanged solar panel 100 would also be advantageous. Figure 3A and 3B , a laminator 300 is shown and described, wherein an output product of the laminator 300 corresponds to the solar panel 100 previously described. Figure 3A It means vertical upward stamping laminator. Figure 3B 300 may include a lower housing 310 and an upper housing 320. When the lower housing and the upper housing 310, 320 are properly joined, a housing is formed, such as Figure 7BAs shown, the housing includes an upper chamber 312 and a lower chamber 322. The lower and / or upper housings 310, 320 may also include a first port 340a and a second port 340b, which may be configured to extract gas from the lower and / or upper chambers or supply gas to the lower and / or upper chambers. Additional ports (not shown) may be provided in the lower and / or upper housings 310, 320 and configured to work in conjunction with one or more pumps and valves to achieve the desired conditions required for lamination, such as heating and / or pressurizing the lamination stack. Again referring to Figure 3A , the first and second shells 310, 320 are configured in a vertically aligned, separated manner so that the laminate stack can be loaded or transferred into the first shell 310. In the vertical upward stamping laminator embodiment, the laminate stack can be transferred into the laminator 300, for example, to form a continuous assembly in a manufacturing plant, and the first and second shells 310, 320 can be physically manipulated in any suitable manner so that the lower shell can be sealed to form a chamber, and corresponding vacuums can be applied to the lower chamber and the upper chamber. For example, the entire assembly corresponding to the lower shell 310 and the laminate stack can be pushed toward the upper shell 320, while the upper shell 320 is stationary. For another example, the surface of the mold 330 can be flush with the top edge of the lower shell 310, so that the mold 330 protrudes beyond the confines of the lower chamber 312; this can facilitate the entry and exit of the mold into the laminator 300.

[0075] The upper housing 320 may also feature a membrane 324 or diaphragm configured to achieve separation between the upper chamber 312 and the lower chamber 322. In this case, the membrane 324 may refer to a flexible membrane that is resistant to pressure and / or heat; the membrane 324 may be made of a rubber material (e.g., silicone) or other suitable material that is resistant to pressure and heat. In an alternative embodiment, the membrane 324 may be replaced by one or more pistons that, when actuated, engage the cover plate to apply pressure to the laminate stack. The lower housing 310 may also feature a seal 314 (e.g., an O-ring) and one or more lift pins 316 (e.g., a seal 314 or ... Figure 7B ). Alternatively, seal 314 may be coupled to upper housing 320. Lower housing 310 may also feature mold 330. Mold 330 may be coupled to lower housing 310 in any suitable manner; for example, it may be located within a groove configured in lower housing 310.

[0076] Figure 4A The mold 330 shown in FIG. 1 may also feature one or more heaters 350a, 350b, 350c. The heating elements 350a, 350b, 350c may be bonded and / or adhered to the inner surface of the mold to match the surface of the solar panel 100 in an offset manner. The heating elements 350a, 350b, 350c may be continuous or divided into multiple regions, such as Figure 4ASimilarly, the heating element can be bonded to Figure 4A The surface not shown in the figure is the surface opposite to the surface on which the heating elements 350b, 350c are arranged. The heating elements 350a, 350b, 350c can be of one or more types, including resistive heaters, fluid channel heaters, or infrared heaters. In order to facilitate the formation of a minimum thermal gradient on the laminate stack, one or more heating elements 350d can also be arranged in the upper housing 320, such as Figure 4B If the heating element is of the infrared radiation type, the membrane 324 should be substantially transparent to such radiation. Alternatively, forced hot air may be used to convectively heat the mold 330 and / or the membrane 324, followed by conduction heating of the lamination stack.

[0077] Typically, to facilitate achieving minimal thermal gradients, the heating elements (e.g., 350a, 350b, 350c, 350d) may be coupled to Figure 5A 310 , or any of the exemplary features shown in the drawings may be integrated or arranged thereon. For example, the element may be disposed on or in the interior of the lower housing 310, disposed on or in the mold 330, disposed on or in the lower tray 360, disposed on or in the upper tray 370, and / or disposed on or in the upper housing 320. The one or more heating elements may be powered in any suitable manner, such as by a cable (not shown) configured to enter the lower chamber 310 through the seal 314, or by an electrical feed-in device and cable passing through the lower housing 310 and / or the upper housing 320, or by a power source coupled to the laminate stack located in the lower chamber 310 during the lamination process. In addition, the heating element 350 may be any type of heating element that convects, conducts, and / or radiates heat to the laminate stack, including, but not limited to, resistive heating elements, forced hot air, fluid heating channels, and infrared radiation (IR) lamps.

[0078] Laminated tray

[0079] Apart from Figure 3A and 3B In addition to the laminator 300 including the mold 360, lift pins 316, and upper and lower heating elements 320, 310, the laminating tray can also provide advantages for improved assembly, handling, lamination, production integration, automation, control and yield of hyperbolic (and flanged) solar panels. Figure 5BA representative lower tray 360 and upper tray 370 are shown, where either or both trays 360, 370 may be used. During the manufacturing process, solar panel 100 is susceptible to damage from particles and other foreign matter in the laminator, as well as tooling defects in the laminator itself (e.g., scratches or dents in the mold). In addition, handling of the components before and after lamination is a problem due to the potential for damage to the components and / or the finished panel. In addition, solar cells 210 are fragile and can be easily damaged during the bending process. Therefore, trays 360, 370 can be used to alleviate these and other problems. In particular, the trays 360, 370 can be used to: support the laminated components prior to lamination; reduce or eliminate damage caused by handling solar panel 100 components (e.g., preforms); transport the laminated stack as it is being assembled; align the individual components of the laminated stack during assembly; protect the laminated stack from defects in the laminator environment and / or tooling; allow uniform distribution of temperature and pressure during the lamination process; allow gentle and controlled bending of the solar cells during the lamination process; impart a controlled surface finish to the laminate; reduce or eliminate damage caused by handling the finished solar panel 100; facilitate loading / unloading of the laminator 300; help protect the laminating equipment from overflow of the encapsulant; and provide an interface for embedding a release layer or a surface on which a release agent can be set.

[0080] refer to Figure 5A and 5B , the lower laminate tray 360 and the upper laminate tray 370 may have offset shapes corresponding to the bottom and top surfaces of the laminate stack, respectively. The trays 360 and 370 may be made of any suitable material, such as metal, hard polymer or glass. The material of the metal trays 360 and 370 may include aluminum, steel, stainless steel, etc. The metal trays 360 and 370 may be formed by any suitable process, such as stamping, milling, hydraulic forming or machining. The surface finish of the metal trays 360 and 370 may be formed by any suitable process, such as machining, polishing, sandblasting or etching. The polymer trays 360 and 370 may be formed by any suitable process, such as molding or extrusion and thermoforming. The glass trays 360 and 370 may be molded or formed by flat glass by any suitable process, such as by press molding or sag molding. Textures may be imparted on the surface of the upper tray facing the cover plate so that the textures are transferred to the cover plate during lamination.

[0081] The upper tray 370 may have a shape that is offset from the lower tray 360, taking into account the final thickness of the laminate, such as Figure 5B Reference Figure 5A, the trays 360, 370 may also include an alignment method between them, which may take the form of a reference point, feature or reference. In this embodiment, alignment is achieved by means of pins 362 and holes 372 respectively disposed in the lower tray 360 and the upper tray 370. If the substrate 120 and the cover plate 130 preforms extend to the tray flange, matching holes may also be provided therein. Alternatively, alignment between two or more components of the laminated stack, for example, alignment between the lower tray 360 and the substrate 120, may be achieved using printed, embossed, recessed or machined reference points. Another option is to achieve correct alignment by using a reference, such as a vertical surface of any pair of elements joined in the laminated stack. For example, any two or more elements may be aligned by integral or external joining using an edge or corner surface. Finally, the upper tray 370 may be configured to impart a texture (e.g., an anti-reflective texture) to the outer surface of the solar panel. In this method, a texture is applied to the lower surface 374 of the upper tray 370 and transferred to the cover sheet 130 under the influence of pressure and heat.

[0082] In alternative embodiments, one or more of the molds 330 and / or trays 360, 370 may be omitted from the illustrated configuration. In alternative embodiments, the mold 330 may be integrated with the lower housing 310. In yet another embodiment, the upper tray 370 may be integrated with one or more upper pistons to form a pressure element. Similarly, the laminator 300 described herein may be configured to accept a laminate stack having any component arrangement. For example, Figure 5A The arrangement shown in , it should not be limited thereto.

[0083] Stacking / tray alignment

[0084] Alignment of the solar panel 100 component layers is important both when assembling the laminate stack and during the lamination process. Superstrate / substrate misalignment may result in panels that are oversized and poorly mated with edges, frames, and other higher-level components. Additionally, alignment between the laminate stack components and between the laminate stack and the lower tray 360 or mold 330 must be maintained during the lamination process. Movement of the superstrate 130 relative to the substrate may expose the encapsulant, resulting in moisture ingress along non-overlapping edges. Finally, movement of the entire laminate stack relative to the trays 360, 370, or mold 330 may result in undesirable panel asymmetry or distortion.

[0085] To prevent the laminate stack assembly from shifting after alignment and assembly, a temporary adhesive in the form of tape 380 may be applied to the edges of the laminate stack, such as Fig. 6A As shown. The tape 380 is preferably thin, compressible and able to withstand the lamination temperature. For example, a polyimide-based tape may be used, such as To prevent the aligned, assembled and taped laminate stack from shifting relative to the lower tray 360 or the mold 330, the same tape 380 may be used between the stack and the tray 360, also as shown in FIG. Fig. 6A After lamination, the two sets of tapes 380 are removed from the panel 100. The adhesive of the tapes 380 is preferably residue-free and leaves a clean panel surface.

[0086] The tape 380 method can be implemented manually and represents a proven alignment solution, for example, in low-volume production. Automation or other solutions to this method must be developed for high-volume production. In high-volume production, printed, embossed or other marking method fiducials combined with machine vision can be used for critical alignment of components (such as solar cell arrays) that are not easily combined with fiducials. In the presence of component fiducials, such as substrate or cover plate edges, passive alignment is preferred. While this may be beneficial to the lamination stack assembly process, additional challenges arise when the components are heated in the lamination chamber. Maintaining alignment between the lamination stack and the tray requires room for expansion or contraction of the panel relative to the tray. For example, for polymer substrates and cover plates, the panel 100 will expand significantly relative to the aluminum tray (e.g., 360, 370). On the other hand, for glass substrates 120 and cover plates 130, the panel 100 will shrink relative to the aluminum tray (e.g., 360, 370). Therefore, a feasible solution will accommodate this expansion or contraction while providing a centering force to keep the panel 100 aligned with the tray 360, 370 or mold 330.

[0087] Lifting pin

[0088] like Figure 6B As shown, one or more lift pins 316 can facilitate loading and unloading of the lamination chamber. During the loading operation, in one embodiment, the stack can be lifted onto the surface of the mold 330 using the pin array 316 to receive the lower tray 360 and the laminate stack and pre-align it to the mold 330. The pin array 316 can provide clearance for a forklift loader or a robotic end effector. The hot laminate 100 can also be easily unloaded. The lift pins 316 also facilitate controlled heating of the tray and laminate stack, which are at ambient temperature when loaded. The heating is preferably controlled by heat conduction through the mold 330. However, the material selection of the lift pins 316 can be modified because metal has sufficient thermal conductivity to increase the temperature of the tray 360 and the laminate stack at the contact point even in the elevated state, and this temperature increase may be sufficient to induce localized curing of the encapsulation layer, resulting in uneven curing of the panel 100. Therefore, the material selection can include insulating materials such as glass, ceramics, porous or fiber materials.

[0089] To prevent thermal conduction between the lift pin 316 and the laminate stack, a thermally insulating material may be provided on the portion 316' (eg, the end 316') of the pin 316 that protrudes from the mold 330, such as Figure 6B As shown. Alternatively, insulating material 316' may be arranged between the end and the lift pin at a height above the mold surface 330. The material is preferably configured to withstand the high temperatures of the lamination process and may be selected from a group of high temperature polymers, such as polyetheretherketone (PEEK), which has a melting temperature of 343°C. Other insulating materials may be used, such as glass, ceramics, porous or fibrous materials, etc., but are not limited to these. The length of the insulating material at the end of the replacement pin 316 determines the total thermal resistance between the pin 316 and the tray 360. In turn, the thermal resistance must be sufficient to reduce the temperature of the encapsulation layer to prevent premature curing, but must be high enough to form a cold spot when the tray 360 contacts the mold 330.

[0090] General Operation

[0091] Figures 7A-7D The general operation of a laminator 300 for producing a hyperbolic solar panel 100 is described. Fig. 7A In the first view shown, the laminator 300 is loaded with a laminate stack. To achieve the loading step, the upper housing 320 is separated from the lower housing 310 by a vertical lifting method to open the lower chamber 312. Alternatively, the upper housing 320 can be opened by a hinged flap method (see Figure 3B ). The laminate stack can be loaded into the lower housing 310 manually or robotically. The laminate stack (shown here in an exploded view) is received in the lower chamber 312 by lift pins 316a, 316b, which hold the stack above the preheated mold 330. The laminate stack may include, from bottom to top, a lower tray 360, a substrate 120, a lower encapsulation material 112a, a solar cell array 200 including at least one solar cell 210, an upper encapsulation material 112b, a flanged cover sheet preform 130, and an upper tray 370. The mold 330 may be heated by one or more heating elements 350a, 350b disposed therein. The upper chamber 322 may also be equipped with one or more heating elements 350d. In addition to facilitating loading, the lift pins 316a, 316b are also used to prevent uncontrolled heating of the laminate stack during loading. Alignment of the laminate stack may be achieved by the flanged cover sheet 130 and one or more alignment pins 362 disposed on the lower tray 360. Complementary holes 138, 372 may be provided in the panel preform 130 and the upper tray 370, respectively.

[0092] exist Figure 7B300, the lift pins 316a, 316b can be retracted into the lower housing 310 of the laminator 300, thereby lowering the laminate stack to the mold 330. The shape of the lower tray 360 is preferably to promote good thermal contact between the tray 360 and the mold 330. In this view, the laminate stack appears in an assembled, folded state, with one or more alignment pins 362 of the lower tray 360 engaging the openings 138 and 372 of the superstrate 130 and the upper tray 370, respectively. It should be noted that since the cells 210 of the solar cell array 200 are generally relatively rigid and flat, air gaps may occur between the substrate 120 and the superstrate 130, and between the superstrate 130 and the lower tray 360. Next, the upper housing 320 is pushed toward the lower housing 310, thereby sealing the lower chamber 312 with the aid of the O-ring 314. The O-ring 314 can be a gasket or any other type of seal for sealing the lower chamber 312 to form a vacuum. The lower chamber 312 and the upper chamber 322 are evacuated through vacuum ports 340a and 340b, respectively, thereby eliminating air between the layers of the laminated stack. Since there is no pressure difference between the lower chamber and the upper chamber 312, 322, the diaphragm 324 remains in a relaxed state. While the chambers 312, 322 are evacuated, the laminated stack is heated by means of one or more heating elements 350a, 350b, 350d disposed in the mold 330 and / or the upper housing 320.

[0093] In the third view shown in FIG6C , vacuum is released from the upper chamber 322 through the vacuum port 340 b, and the membrane 324 is bent into the lower chamber. The membrane 324 engages the upper tray 370 and applies pressure to the elements of the laminate stack (e.g., elements 360, 120, 110, 130, 370). Alternatively, if the upper tray 370 is omitted, the membrane 324 can directly engage the superstrate 130. In any such alternative, the laminate stack is maintained under appropriate vacuum, heat, and pressure conditions for the prescribed curing time of the laminate.

[0094] exist Fig.7D In the fourth view shown, the vacuum in the lower chamber 312 can be released through the vacuum port 340a, and the diaphragm 324 returns to its relaxed position. Next, the upper housing 320 is separated from the lower housing 310, thereby opening the lower chamber 312. Finally, the lifting pins 316a, 326b lift the laminate stack (e.g., 360, 100, 370) to the unloading position. At this point, the laminate stack can be removed from the laminator 300 manually or robotically.

[0095] like Figures 7A-7D and Figure 8As shown, the total cycle time of the laminator 300 can be defined as the time between one stack entering the laminator 300 and the next stack entering the laminator 300. Therefore, the cycle time is an important factor related to the overall efficiency of the manufacturing equipment (such as the continuous lamination equipment 400 of patent application No. 18 / 168,274) for producing solar panels 100. For example, in one method considered within the scope of the present invention, for each cycle, the laminate stack is located in the laminator 300 for about 15 to 20 minutes, including the following steps: (i) evacuating to achieve a vacuum, wherein curing / heating can be considered to have begun, which lasts for about 1-3 minutes; (ii) pressurizing and curing / heating for the remaining time, with a total cycle time of about 15-20 minutes. For another example, a cycle time of 12 minutes can be achieved, the latter part involving a combined heating and pressurization state of the laminate stack, which lasts for about 6 minutes.

[0096] Figure 8 An exemplary flow chart for using the laminator 300 is shown. The steps may include: step 174a, loading a laminate stack including a tray (if present) into the lower chamber of the laminator 300; step 174b, closing the lid and evacuating air from the lower and upper chambers 312, 322 to remove air from between the layers of the laminate stack; step 174c, preheating the laminate stack; step 174d, applying pressure to the laminate stack by an appropriate method, such as by applying mechanical pressure using a piston or by a pressure differential applied to the diaphragm 324; step 174e, maintaining the lamination conditions (i.e., chamber pressure, stack temperature, and diaphragm pressure) for an appropriate time interval; step 174f, returning the chambers 312, 322 to loading / unloading conditions, such as atmospheric pressure, loading / unloading temperature, and relaxed diaphragm; and step 174g, removing the laminate stack including the trays 360, 370 from the lower chamber of the laminator 300.

[0097] Mold geometry and panel edge effects

[0098] The matching of the film to the curvature of the lamination stack and the tray or mold is critical to the successful manufacture of a durable and reliable curved solar panel 100. Figure 5A In the discussion of Figures 8B, the terms "die" 330 and "tray" 360 are interchangeable. In a planar laminator, the film is typically located near the lamination stack. When the pressure above the film is increased, the film bends downward and makes initial contact at the center of the lamination stack. The contact area expands as the pressure increases until the entire panel is in contact with the film.

[0099] In laminators with curved dies (eg, 330), the process is more complicated. Figures 9A-9D 3 shows the deformation of the membrane 324 and the interaction with the die having a radius R as the pressure on the membrane 324 increases. Without pressure, the membrane 324 does not bend, as shown in FIG. Fig.9A As shown. Fig. 9B In , when the pressure increases to an intermediate value, the film 324 contacts the center of the mold, and the contact point progresses to a contact angle θ. Since the film 324 is fixed at the edge, the film 324 becomes increasingly stretched while maintaining its distance from the center. Fig. 9C In , the additional pressure forces the film 324 to move further down the side of the mold, thereby increasing the contact angle. Fig.9D In the embodiment of the present invention, the pressure forces the film 324 to contact the mold 330 completely, including the vertical surfaces.

[0100] Since in a flat laminator the contact point of the film 324 is fixed due to friction. Unlike a flat laminator, when the film 324 is wrapped around a curved surface, the film displacement D can be significantly larger and θ can change significantly, where D varies with sinθ and by definition D=0 at the initial contact point. The fixation of the film 324 at the interface of the mold 330 and the vertical displacement of the film 324 cause the film 324 to stretch more as it moves down the side of the mold 330. This produces an elongation or strain ΔL that increases with θ, as Fig. 10A As shown. Maximum strain ΔL max Occurs at the vertical surface of the mold at θ = 90° and is related to the maximum displacement D max The strain from θ=90° is ΔL=ΔL max When θ=0°, ΔL=0, and the relationship ΔL=ΔL is followed. max sinθ. In other words, the strain is zero at the first point of contact (neglecting membrane displacement up to that point) and develops in a nonlinear fashion to a maximum value at θ = 90°. The strain in the unsupported portion of the membrane 324 is constant and equal to the strain at the point of contact.

[0101] For a curved solar panel 100 disposed on a mold 330 and in direct contact with the film 324, the laminate stack thickness t must be considered. Fig. 10B Shows the settings in Fig. 10A The laminate stack on the mold 330 is shown in Figure 1, where a moderate amount of pressure is applied. The membrane 324 is in full contact with the panel and the amount of bending is slightly beyond the edge of the panel. At the edge of the bent panel, a reactive shear force F s , which is equal to the product of the elastic modulus of the membrane and ΔL. Therefore, F s ∝D. In other words, the greater the pressure required for the membrane 324 to contact the edge of the panel, the greater the pressure F s The larger the magnitude of F s tangent to the surface of the cladding sheet, so no normal force is applied. However, with additional pressure, the membrane 324 will bend downward through the vertical gap between the laminate stack and the mold surface, causing the force F to be directed downward, as shown in FIG. Fig. 10CIn this direction, F is tangential (F s ) and normal (F n ) directions. As before, F s The effect on the rigid cover plate 130 is not significant. However, F n Now acts as a local pressure on the edge of the panel. Since the encapsulation layer of the core 110 is soft at the lamination temperature, the cover 130 may respond to F n This causes the core 110 to be squeezed, forcing some of the potting compound away from the edge and forming a bow near the edge of the cover sheet 130. In other words, the core at the edge of the panel experiences high pressure, while relatively low pressure areas appear within the panel core near the edge.

[0102] This has the following effects: (i) reducing or preventing outgassing at the panel edge, and (ii) allowing bubbles to accumulate in low pressure areas. In addition to the reduced appearance quality, uneven lamination also presents reliability risks. In summary, the interaction between the laminate stack thickness, the mold geometry, and the film 324 will produce uneven pressure. Specifically, as the displacement of the film 324 at the panel edge increases, the laminate stack becomes thicker, and the exit angle of the film 324 from the panel edge becomes more perpendicular to the panel tangent, the greater the bending moment on the panel edge during lamination.

[0103] exist Fig.11A In the first solution to this problem shown, the angle of the film 324 near the edge of the panel is changed from a subtangent angle to a tangent or supertangent angle 382. This is achieved by the shape of the mold 330 near the edge of the panel. In this embodiment, the obtuse angle of the mold 330 relative to the tangent of the panel surface prevents the film 324 from moving downward when it reaches the edge of the panel. This keeps F substantially aligned with the panel tangent, thereby reducing or eliminating F n , thus preventing squeezing, bending and bubble formation within the panel.

[0104] exist Fig. 11B In an alternative embodiment, a groove 384 may be formed (e.g., by machining) in the mold 330, the depth of which is equal to the thickness of the laminated panel. In this context, substantially equal means within manufacturing tolerances. When the laminated stack is compacted, the top of the cover sheet is flush or substantially flush with the adjacent mold 330 surface. Even with a small gap between the panel and the mold, the film 324 will not deflect significantly, thereby maintaining F substantially consistent with the tangent direction of the panel 100.

[0105] In another embodiment, if Fig. 11CAs shown, a groove 386 can be formed in the tray 360, such as by a stamping process. A matching groove 384 can be formed (e.g., machined) in the mold 330 to allow the required thermal contact with the tray 360. When the laminate stack is pressed, the top of the cover sheet 130 is flush with the adjacent surface of the tray 360. Even with a small gap between the panel 100 and the tray 360, the film 324 will not deflect significantly, thereby keeping F substantially consistent with the panel tangent and minimizing or eliminating F n .

[0106] In another embodiment, if Fig.11D As shown, a riser 388 may be formed in the tray 360, for example, by a stamping process. The riser 388 forms a boundary, such as a continuous perimeter, around the laminate stack, which helps to lift the film to a level close to the surface of the cover sheet 130 so that the F s The advantage of this method is that it allows the mold 330 surface to be free of grooves.

[0107] In another embodiment, if Fig.11E As shown, the riser 389 can be formed in the tray, for example, by an assembly process. The riser 389 can be formed or machined separately and fixed to the tray 360 or the mold 330 by adhesive, fasteners, welding, brazing or other connection methods, depending on the materials used. The riser 389 forms a boundary around the laminate stack, such as a continuous perimeter, which helps to lift the film 324 to a level close to the surface of the cover sheet 130, so that F is consistent with the panel tangent. The advantage of this method is that it allows the mold 330 surface without grooves.

[0108] Die and / or tray alignment

[0109] Reference now Fig. 12A and 12B, the mold 330 and the tray 360 (e.g., 360a and 360b) are typically precision-made to share a mating interface so that heat is transferred from the mold to the tray by thermal conduction. Any gap between the mold 330 and the tray 360 may cause heat to be transferred by convection, which is much less efficient than thermal conduction. Therefore, incomplete physical contact between the mold 330 and the tray 360 may cause uneven heating within the lamination stack. Uneven heating, in turn, may cause insufficient or excessive curing of the encapsulant, incomplete venting and bubble formation, poor edge bonding, delamination, and / or other panel failure modes. For these reasons, it is desirable to mechanically couple the mold 330 and the tray 360 to provide uniform conduction, preferably throughout the lamination process, but especially at the lamination temperature. However, in a standard lamination process, the mold 330 is typically maintained at or slightly above the lamination temperature, while the tray 360 and the lamination stack are assembled at ambient temperature. This temperature difference may be as high as about 135°C. Assuming that the mold 330 and the tray 360a are made of the same material (e.g., aluminum), thermal expansion will cause the size of the mold 330 to increase relative to the tray, such as Fig. 12A Here, the mold 330 and tray 360a combination, which have vertical side walls and fit correctly at room temperature, now exhibit interference when the mold 330 is at an elevated temperature and the tray 360a is at about room temperature. Only when the tray 360 reaches the temperature of the mold 330 (e.g., Fig. 12B The material tray 360 can correctly match with the mold 330.

[0110] To solve this problem, two methods are provided. Fig.13A and 13B As shown, in the first method, the sides of the mold 330 and the tray 360 are angled to form a stacked configuration. Fig.13A , a cold tray 360 (representatively shown as tray 360c) is lowered onto a hot mold 330. Because mold 330 has expanded relative to tray 360c, tray 360c cannot be completely located on mold 330, leaving a small and uniform gap between the upper portions (e.g., near the lamination stack). In this configuration, uniform convection heating may be applied to tray 360c of the lamination stack near the upper portion of the lamination stack. As tray 360c heats up, it gradually expands and slowly slides down toward mold 330 under the influence of gravity. When tray 360 reaches the temperature of mold 330, representatively shown as Fig. 13B In the middle material tray 360d, the material tray 360 is in full contact with the mold 330. The process is controllable and repeatable, and is therefore suitable for production.

[0111] like Fig.14A and 14BAs shown, in a second method, a tray equipped with flexible features 390 can be placed on or formed in a mold 330. Fig.14A , the vertical side walls of the tray 360 provide clearance for the die 330 when the tray 360 is cooled. A flexible element 390 (e.g., in the form of a punch biasing element 390) can contact the vertical sides of the die 330 and center the tray 360 relative to the die 330. In the cooled state of the tray 360, the biasing element 390 is maximally curved. The curvature of the upper portion of the tray 360 preferably matches the curvature of the die 330 at a common temperature. However, when the die 330 is hot and the tray 360 is cold, the radius of curvature of the tray 360 is less than the radius of curvature of the die 330. Therefore, a small gap 392 appears between the upper portion of the tray 360 and the die 330. Advantageously, this gap 392 is very small and has little effect on the heating of the tray 360. As the temperature of the tray 360 increases, the tray 360 expands and the biasing element 390 contracts to maintain the die / tray alignment. At high temperatures, the biasing element 390 of the tray 360 is minimally bent, and the curvatures of the tray 360 and the mold 330 are equal, as shown in FIG. Fig. 14B Since the tray 360 is in close proximity or contact with the mold 330 during the entire temperature cycle, the process is primarily driven by the precisely controlled temperature of the mold.

[0112] Membrane strain

[0113] Since the curved mold 330 and / or tray 360 occupies a larger chamber volume than a flat laminating surface, the film 324 must be positioned away from the platen or bottom extent of the mold 330 to provide clearance for the mold 330, tray 360, and lamination stack. This in turn requires the film to expand a greater amount relative to the flat laminator film in order to conform to the curved mold and apply pressure to the entire lamination stack. The greater displacement results in high film stress, which can lead to film failure, resulting in laminator downtime and increased production costs, and considering that the chamber also includes sharp corners and edge geometries, causing the film 324 to stretch locally to conform to these features.

[0114] Fig.15A and 15B An example of a chamber having right angle corners and edge features 398 is shown. Fig.15A In FIG. 3 , the membrane 324 has been pulled into the lid using a vacuum to provide clearance for the loaded laminate stack. In this position, the maximum stress point of the membrane 324 is located at the corner 398 of the upper chamber. Fig. 15BIn the embodiment of the present invention, the film 324 has been pulled into the lower chamber using vacuum to provide pressure during the lamination process. Although some higher stress points may be formed around the mold 330, these stress points occur at the intermediate values ​​of the elongation of the film 330 because the last contacted surface coincides with the maximum film elongation. It has been found that after reducing the number of pressurization cycles, film failure may occur at these points. Therefore, the maximum stress point of the film 330 is located at the corner 398 of the lower chamber.

[0115] To solve this problem, two methods are provided. In the first method, Fig.16A and 16B As shown, the edges and corners of the chamber are chamfered 399, rounded, or otherwise made less sharp. The rounded corners 399 can be formed in the housing by a manufacturing process (e.g., machining). Alternatively, the rounded corner features 399 can be manufactured separately, such as by 3D printing, and then assembled into the chamber. Fig.16A In the case of a laminating machine, the film has been pulled into the lid using vacuum to provide clearance for the loaded lamination stack. Fig. 16B In the lamination process, the film has been pulled into the lower chamber using a vacuum to provide pressure during lamination. Fig.16A and 16B In the embodiment of the present invention, the fillet is used to increase the radius of curvature of the stretched film 324, thereby distributing the stress to a larger area and reducing its magnitude. The reduction in the maximum stress experienced by the film 330 increases the number of stress cycles before failure, thereby increasing the production capacity of the laminating machine and reducing costs.

[0116] In the second method, if Fig.17A and 17B As shown, the tension of the membrane 324 in the relaxed state is reduced by introducing a slack portion. Fig.17A Shown is a relaxed film 324 in a closed housing, wherein only the mold 330 is present. The film 324 may rest above the mold 330 and / or otherwise be in contact with the mold 330, depending on its position in the lid and the amount of relaxation present. Fig. 17B The laminator is shown loaded with a slight vacuum applied to the upper chamber to lift the relaxed film 324 into the lid and provide clearance for the lamination stack. Fig. 17B As shown, the initially relaxed membrane needs to travel a shorter distance to fill the lower chamber, thereby reducing membrane strain.

[0117] Vent

[0118] During the lamination process, encapsulation materials release volatile byproducts in a process called outgassing. However, in curved laminator 300, film 324 can surround and temporarily seal the laminate stack on mold 330 or tray 360, thereby preventing some of the gases from escaping. This can result in insufficient cure of the encapsulant. Under certain conditions, trapped gases can form bubbles within the encapsulation layer. In addition to reduced appearance quality, suboptimal lamination also presents performance and reliability risks, such as low clarity, poor edge adhesion, delamination, and other panel failure modes.

[0119] refer to Fig.18 To prevent gas entrapment during the pressure phase of the lamination process, passages such as holes, vents and channels, represented as channels 394 and 396, can be provided on the tray and / or mold. During the pressure phase, venting occurs almost entirely at the edges of the panel. Therefore, the gas escape route is advantageously formed around the periphery of the panel. FIG. 16 follows Fig. 11C An example of a method of manufacturing a plurality of panels 100 is provided in which a stamped tray 360 and a recessed mold 330 are used to prevent the film from inducing stress at the edge of the panel 100. In this embodiment, a vent hole 394 may be formed in the tray 360, such as in the wall of the stamped groove 386. A vacuum channel 395 in communication with the vacuum fluid of the lower chamber through the opening 340a may be formed between the tray 360 and the mold 330, such as between the rounded corners of the stamped tray 360 and the machined corners of the mold groove 386. If additional collection channels 396 are required, they may be machined into the mold 330 in the form of grooves. The grooves 396 may have various profiles, including but not limited to rectangular, square, V-shaped, oval and / or circular, or any shape configured to achieve the desired purpose of exhausting the steam. The grooves 396 can be arranged at various angles, such as perpendicular and / or parallel to the plane of the page, or other non-perpendicular angles, as there are many equivalent configurations that meet the following requirements: (i) the inlet is arranged near the edge of the panel and (ii) the outlet is connected to the lower chamber vacuum.

[0120] postscript

[0121] The description of the foregoing disclosed embodiments is intended to enable those skilled in the art to make or use the present invention. Those skilled in the art will readily appreciate various modifications to these embodiments, and the general principles defined herein may be applied to other embodiments without departing from the spirit or scope of the present invention. Therefore, it is desired that the present embodiments be considered illustrative and not restrictive in all respects, and reference is made to the appended claims and the foregoing description to illustrate the scope of the present invention.

Claims

1. A laminating machine comprising: a lower housing comprising a convex surface having two axes of curvature, the convex surface being selected from the group consisting of: a mold, a lower tray, or the lower tray being operatively engaged to the mold in a physically and thermodynamically complementary manner, The convex surface is adapted to uniformly transfer heat from the heat source to the laminate stack and to support the laminate stack when the laminate stack is joined thereto, The convex surface includes a protrusion formed outwardly therefrom, and the protrusion is formed near a periphery of the laminate stack when the laminate stack is joined to the convex surface, and The convex surface further includes one or more channels formed near the peripheral edge of the lamination stack when the lamination stack is operably coupled to the convex surface, the one or more channels being used to convey vapor away from the lamination stack during lamination; one or more lift pins adapted to move the laminate stack between a first position and a second position, The first position is characterized by the laminate stack being offset from the heat source such that the laminate stack is thermally isolated from the heat source, The second position is characterized by the laminate stack being in thermal communication with the heat source, and the one or more lift pins comprising a thermally insulating portion such that when the one or more pins are in the first position, the thermally insulating portion of the one or more pins thermally insulates the laminate stack from the heat source; as well as an upper housing including a membrane having a first membrane portion proximate to the laminate stack and a second membrane portion surrounding the first membrane portion; The size of the protrusion is designed so that when the film is in a laminated state, the first film portion overlaps with the second film portion, or equivalently, the second film portion forms an obtuse angle around the periphery, Wherein, in the assembled state, the lower shell and the upper shell form a cavity, which is separated by the membrane to form an upper chamber and a lower chamber, the upper chamber has at least one upper rounded corner and an upper opening is formed in the upper shell to remove fluid and / or add fluid to the upper chamber, and the lower chamber has at least one lower rounded corner and a lower opening is formed in the lower shell to remove and / or add fluid to the lower chamber.

2. A laminator system comprising: a lower housing comprising a convex surface having two axes of curvature, the convex surface being selected from the group consisting of: a mold, a lower tray, or the lower tray being operatively engaged to the mold in a physically and thermodynamically complementary manner, The convex surface is adapted to uniformly transfer heat from a heat source to the laminate stack and to support the laminate stack when the laminate stack is joined thereto, and the convex surface including a protrusion formed outwardly therefrom, and the protrusion is formed near a peripheral edge of the laminate stack when the laminate stack is operably engaged to the convex surface; one or more lift pins adapted to move the laminate stack between a first position and a second position, The first position is characterized by deflecting the laminate stack away from the heat source such that the laminate stack is thermally isolated from the heat source, and the second position being characterized by the laminate stack being in thermal communication with the heat source; as well as an upper housing including a membrane; Wherein, in the assembled state, the lower shell and the upper shell form a cavity, which is separated by the membrane to form an upper chamber and a lower chamber, the upper chamber having an upper opening formed in the upper shell to remove fluid and / or add fluid to the upper chamber, and the lower chamber having a lower opening formed in the lower shell to remove fluid and / or add fluid to the lower chamber.

3. A laminator system according to claim 2, wherein the convex surface is the mold and the protrusion is selected from the group consisting of: formed by a supertangent angle, and formed by a groove formed in the mold, the depth of the groove being substantially equal to the thickness of the laminate stack.

4. A laminator system according to claim 2, wherein the convex surface is the lower tray, which is operably engaged to the mold in a physically and thermodynamically complementary manner, and the protrusion is formed by a groove formed in the lower tray, the depth of the groove being substantially equal to the thickness of the laminate stack.

5. A laminator system according to claim 2, wherein the convex surface is the lower tray, which is operably engaged to the mold in a physically and thermodynamically complementary manner, and the protrusion is selected from the group consisting of: formed by a raised portion of the lower tray, and formed by an object placed on the lower tray.

6. The laminator system according to any one of claims 2 to 5, the upper chamber further having a plurality of upper fillets and the lower chamber further having a plurality of lower fillets, the upper fillets and lower fillets being adapted to reduce stress on the film by reducing elongation of the film.

7. According to a laminator system as described in any one of claims 2 to 6, the one or more lifting pins include an insulating portion, so that when the one or more pins are in the first position, the insulating portion of the one or more pins thermally insulates the lamination stack from the heat source.

8. According to a laminator system as described in any one of claims 2 to 7, the convex surface also includes one or more channels formed near the periphery of the lamination stack when the lamination stack is operably engaged to the convex surface, and the one or more channels are suitable for conveying steam away from the lamination stack during lamination.

9. The laminator system according to any one of claims 2 to 8, wherein: The lower tray operably engaged to the mold in a physically and thermodynamically complementary manner further includes a draft angle in a range of greater than 0 degrees to about 30 degrees.

10. A laminator system according to claim 9, wherein the lower tray includes at least one set of relative biasing elements, which are suitable for maintaining the alignment of the tray with the mold when the one or more are moved from the first position to the second position and / or when the heat source begins to transfer heat.

11. A method of laminating a solar panel, comprising the steps of: Providing a laminator system according to any one of claims 2 to 10; providing the laminate stack comprising a substrate, a superstrate, and a core therebetween, the core comprising a solar cell array having at least one solar cell surrounded by an encapsulation material; providing a first vacuum to the upper chamber, thereby deforming the membrane to conform to the upper chamber; moving the one or more lift pins to the first position; superimposing the laminate stack adjacent the convex surface and engaging the laminate stack to the one or more lift pins; Moving the upper housing and / or the lower housing to the assembled state; moving the lift pins to the second position and uniformly transferring heat from the heat source to the laminate stack; providing a second vacuum to the lower chamber when the lamination stack reaches the lamination temperature; releasing the first vacuum from the upper chamber, thereby deforming the membrane such that pressure is applied to the laminate stack and the at least one solar cell of the solar cell array moves along an axis of curvature; maintaining the laminate stack within the pressure, uniform heat transfer, and the second vacuum for a predetermined time to form a laminate; releasing the second vacuum, thereby moving the membrane to an intermediate position; removing the heat source; Disassembling and assembling the upper shell and the lower shell; moving the one or more lift pins to the first position; The laminate is removed from the laminator system.

12. The method of laminating solar panels of claim 11 further comprising the step of removably securing the cover sheet to the substrate using adhesive tape.

13. The method of laminating solar panels according to claim 12 or 13, further comprising the step of removably securing the laminate stack to the lower tray using tape.

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