Back film coating apparatus
By designing a back film coating equipment, the automated cutting, conveying, positioning and pressing of the back film were realized, which solved the problem of low production efficiency in the photovoltaic panel back film coating process and improved the coating quality and efficiency.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- NINGBO RING ELECTRONICS CO LTD
- Filing Date
- 2026-05-14
- Publication Date
- 2026-07-21
Smart Images
Figure CN122232164B_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of film coating technology, and in particular to a backing film coating device. Background Technology
[0002] As a core component of photovoltaic panels, the backsheet primarily serves to provide electrical insulation, mechanical support, moisture barrier, and power enhancement. In existing processes, operators need to use cutting equipment to cut the backsheet into sheets of the appropriate size. These sheets are then placed onto the back of the photovoltaic panel manually or by a robotic arm, and finally heated in an oven to cure them. The inventors believe that the production efficiency of the aforementioned backsheet coating process for photovoltaic panels needs improvement; therefore, they request a backsheet coating device to enhance coating efficiency. Summary of the Invention
[0003] In order to improve the production efficiency of back film coating, this application provides a back film coating equipment.
[0004] The back film coating device provided in this application adopts the following technical solution: A back film coating device includes a frame, a film cutting mechanism mounted on the frame, a coating mechanism mounted on the frame, an air-floating platform located on the output side of the film cutting mechanism and used to receive the back film output after cutting by the film cutting mechanism, a first driving mechanism for driving the air-floating platform to move, a conveyor belt mechanism located below the air-floating platform and used to transport photovoltaic panels to the area below the coating mechanism, and a positioning mechanism for adjusting the position of the photovoltaic panels; the coating mechanism includes a coating suction cup, a first lifting member for driving the lifting and lowering of the coating suction cup, and a device mounted on the frame. A film-coating suction cup and a spot welding assembly for spot welding the edges of a photovoltaic panel; the film-coating suction cup is used to adsorb the back film and press the back film onto the photovoltaic panel; the air flotation platform has a placement area for laying the back film; the air flotation platform is provided with an air flotation structure in the placement area, the air flotation structure includes an air cavity opened inside the air flotation platform, a first air hole opened in the placement area near the back film and communicating with the air cavity, and a second air hole communicating with the air cavity and connected to an external wind turbine; the number of the first air holes is multiple, and the multiple first air holes are evenly arranged in an array.
[0005] By adopting the above technical solution, a streamlined automated operation is achieved for backsheet cutting, conveying, photovoltaic panel positioning, and photovoltaic panel and backsheet lamination assembly. An air-floating platform receives the cut backsheet and, with the aid of a first drive mechanism, transfers it to the lamination station. Simultaneously, a conveyor belt transports the photovoltaic panel to the lamination mechanism, where a positioning mechanism precisely positions it. This significantly improves the automation level and efficiency of the lamination process, reducing the frequency of manual intervention and labor intensity. The lamination mechanism uses lamination suction cups to adsorb the backsheet, and a first lifting component drives the suction cups to rise and fall, ensuring accurate pressing of the backsheet onto the photovoltaic panel surface. Furthermore, spot welding components integrated on the suction cups can spot weld and fix the edges of the photovoltaic panel during lamination, reducing the risk of the backsheet detaching from the photovoltaic panel during transport. The entire process requires no manual intervention, automatically completing a series of lamination steps including cutting, conveying, alignment, and pressing, effectively improving the production efficiency of backsheet lamination. The air flotation platform features an air flotation structure in the placement area. When air is supplied to the second air vents via an external fan, the gas passes through the air chamber and is then blown out through multiple uniformly arranged first air vents, forming a uniform and stable air cushion layer between the backing film and the placement area. This air cushion layer keeps the backing film in a suspended state, significantly reducing the frictional force experienced by the backing film when moving and adjusting its position on the air flotation platform. This reduces the probability of wear or electrostatic adsorption damage caused by direct contact between the lower surface of the backing film and the air flotation platform. Simultaneously, the uniform array arrangement of the multiple first air vents ensures balanced stress on all parts of the backing film, reducing wrinkles, shifts, or localized tensile deformation during transport, and improving the alignment accuracy and bonding quality of subsequent lamination processes.
[0006] Optionally, the fan device has a positive pressure state and a negative pressure state; in the positive pressure state, the fan device blows air into the second air hole, causing the back film to suspend on the air flotation platform; in the negative pressure state, the fan device draws air through the second air hole, causing the back film to adhere to the air flotation platform, which facilitates the adhesion of the film-coating suction cup.
[0007] By adopting the above technical solution, the blower equipment has two working states: positive pressure and negative pressure. Under positive pressure, airflow enters the air chamber through the second air hole and exits through the first air hole, suspending the backsheet above the placement area, facilitating stable transport of the backsheet. Under negative pressure, the blower equipment draws in air through the second air hole, creating an adsorption force between the air chamber and the first air hole, firmly adhering the backsheet to the surface of the air flotation platform. This ensures the backsheet remains stable during transport with the air flotation platform, preventing shifting or displacement, improving the accuracy of backsheet transport, and providing a good foundation for the subsequent precise adsorption of the backsheet by the laminating suction cup, thus guaranteeing the alignment accuracy of the laminating process.
[0008] Optionally, the spot welding assembly includes a spot welding body and a second lifting component for driving the spot welding body to rise and fall; the spot welding body includes an outer shell, a soldering head installed in the outer shell, a heating element installed in the outer shell for heating the soldering head, and a heat insulation sleeve covering the outside of the heating element; a phase change element is disposed between the heating element and the soldering head; the phase change element includes a phase change housing and a phase change material filled in the phase change housing.
[0009] By adopting the above technical solution, the spot welding assembly uses a second lifting component to drive the spot welding main body to rise and fall, achieving precise spot welding operations on the edges of photovoltaic panels. The spot welding main body integrates a soldering head and a heating element within its outer shell. A heat insulation sleeve covers the heating element, effectively reducing heat loss to the outer shell and surrounding components, lowering heat loss, and preventing high-temperature damage to adjacent components. A phase change element is installed between the heating element and the heat insulation sleeve, allowing excess heat generated during heating element operation to be absorbed and stored by the phase change material. When the heating element's intermittent operating temperature decreases, the phase change material releases the stored heat, maintaining the soldering head temperature within a stable operating range and reducing large temperature fluctuations. This structure keeps the soldering head's operating temperature within a more stable range, avoiding problems such as unstable weld quality, incomplete welds, or over-welds caused by sudden temperature rises or falls, significantly improving the consistency and reliability of spot welding quality, and extending the service life of the heating element and soldering head.
[0010] Optionally, the output shaft end of the second lifting component is provided with a fixed seat, the fixed seat is provided with a spherical frame, the spherical frame is provided with a ball joint, and the end of the spot welding body away from the soldering head is connected to the end of the ball joint extending from the fixed seat.
[0011] By adopting the above technical solution, the output shaft end of the second lifting component is connected to the spot welding body through a ball joint in the fixed seat, enabling the spot welding body to have a certain degree of angle adaptive adjustment capability during the lifting process. When there are slight unevennesses on the surface of the photovoltaic panel or slight positioning deviations, the spot welding body can swing slightly around the center of the ball joint with multiple degrees of freedom, automatically adjusting the contact posture between the soldering head and the edge of the photovoltaic panel to ensure that the soldering head and the welding point are fully aligned. This structure effectively compensates for the adverse effects of workpiece surface shape and position errors and mechanism assembly errors on welding quality, significantly improves the spot welding success rate, and ensures the consistency of weld quality.
[0012] Optionally, the number of spot welding components is two sets, and the two sets of spot welding components are symmetrically arranged on both sides of the coating suction cup; the coating suction cup is provided with an adjustment mechanism for driving the two spot welding components to move relative to each other, the adjustment mechanism includes a first lead screw, a second lead screw, and a dual-head motor for driving the first lead screw and the second lead screw to rotate synchronously; the two spot welding components are respectively slidably mounted on the first lead screw and the second lead screw; the first lead screw and the second lead screw are coaxially arranged on the mounting beam of the coating suction cup, and the threads of the first lead screw and the second lead screw have opposite directions and their close ends are respectively fixedly connected to the two output shafts of the dual-head motor through couplings.
[0013] By adopting the above technical solution, two spot welding components are symmetrically arranged on both sides of the coating suction cup. This allows for simultaneous spot welding and fixing of the back film edges on both sides of the photovoltaic panel during coating, ensuring the back film is immediately positioned and constrained after pressing. This reduces the likelihood of slippage, warping, or detachment of the back film during subsequent processes or equipment vibration, significantly improving coating stability and yield. The dual-head motor in the adjustment mechanism drives the first and second lead screws to rotate synchronously, causing the two spot welding components to move closer or further apart, achieving rapid and precise adjustment of the distance between them. This structure can adapt to the coating and spot welding needs of photovoltaic panels of different sizes.
[0014] Optionally, the positioning mechanism includes a first positioning component located at the front end of the conveyor belt mechanism and second positioning components located on both sides of the conveyor belt mechanism; the first positioning component includes an abutting crossbar that abuts against the front edge of the photovoltaic panel, a first driving member for driving the abutting crossbar to rise and fall, and a second driving member for driving the abutting crossbar as a whole to move back and forth along the conveying direction of the conveyor belt mechanism, wherein the abutting crossbar is a cylindrical rod; the second positioning components respectively include a positioning push rod, a positioning ring block installed on the positioning push rod, and a third driving member for driving the positioning push rod to move; the side wall of the positioning ring block abuts against the side wall of the photovoltaic panel.
[0015] By adopting the above technical solution, the positioning mechanism uses a combination of a first positioning component and a second positioning component to perform multi-point positioning from the front end and both sides of the photovoltaic panel. The abutment crossbar of the first positioning component moves to a set position under the drive of the second driving component, and then is lifted by the first driving component to achieve reliable abutment and limitation of the front edge of the photovoltaic panel. The positioning push rod of the second positioning component extends under the drive of the third driving component, causing the side wall of the positioning ring block to abut against the side wall of the photovoltaic panel, completing the lateral positioning. This multi-point cooperative positioning method can effectively reduce the placement deviation of the photovoltaic panel on the conveyor belt mechanism, ensuring that each photovoltaic panel is in a uniform and definite reference position when entering the lamination station, thereby guaranteeing the lamination alignment accuracy between the back film and the photovoltaic panel.
[0016] Optionally, the film cutting mechanism includes a feeding assembly, a correction assembly for correcting the deviation of the back film, a gripping assembly for clamping the front edge of the back film, a second driving mechanism for driving the gripping assembly to move, a punching assembly located between the correction assembly and the gripping assembly, a cutting blade arranged side by side with the punching assembly, and a third lifting member for driving the cutting blade to rise and fall; the gripping assembly for gripping the back film has a punching station and a cutting station after being driven by the second driving mechanism, the back film is punched through the punching station, and then cut by the cutting station.
[0017] By adopting the above technical solution, the film cutting mechanism can automatically complete a series of processes including backsheet feeding, alignment, punching, and fixed-length cutting. This eliminates the need for manual preparation and positioning of the backsheet before cutting, reducing the time and errors associated with manual cutting. The alignment component corrects the position of the backsheet during transport, reducing belt deviation and ensuring the accuracy of subsequent punching and cutting positions. After the gripping component holds the front edge of the backsheet, the second drive mechanism propels it sequentially through the punching and cutting stations, cutting the backsheet to the set size according to production requirements. This meets the production needs of photovoltaic modules of different specifications. The entire film cutting process is seamlessly automated, effectively improving the efficiency and cutting accuracy of the film cutting process, and providing standard-sized and accurately positioned backsheet raw materials for subsequent lamination processes.
[0018] The gripper assembly includes a mounting rod slidably mounted on the frame and arranged laterally, and a plurality of pneumatic grippers fixedly mounted on the mounting rod. The plurality of pneumatic grippers are evenly spaced along the length direction of the mounting rod. The second drive mechanism is mounted on an inner side wall of the frame. The slide of the second drive mechanism is fixedly connected to the mounting rod. The frame is provided with a first guide rail on the side opposite to the second drive mechanism, which cooperates with the mounting rod. The first guide rail has a cuboid structure and extends along the back film conveying direction. The mounting rod has a first groove that cooperates with the first guide rail.
[0019] By adopting the above technical solution, the gripping assembly is specifically equipped with multiple pneumatic grippers that can evenly grip the front edge of the back film, resulting in uniform force and reducing localized stretching and deformation of the back film during the pulling and conveying process. The mounting rod slides between the slide table of the second drive mechanism on both sides of the frame and the first guide rail, making the movement process more stable and further ensuring the positional accuracy of the back film conveying, thus making the punching and cutting positions more accurate.
[0020] Optionally, the punching assembly includes a mounting base mounted on the frame, a punching component mounted on the mounting base, and a fourth lifting component for driving the punching component to move up and down; the mounting base has a clearance groove along the movement direction of the back film; the top wall of the clearance groove has an arrangement through hole for the punching component to be moved; the bottom wall of the clearance groove has an avoidance through hole corresponding to the arrangement through hole.
[0021] By adopting the above technical solution, the mounting base of the punching assembly has clearance slots along the direction of the back film transport. This allows the back film to pass smoothly through the mounting base during the unfolding process driven by the gripping assembly, without being obstructed. Simultaneously, punching can be performed during the back film unfolding process without additional machine stops for position adjustments, effectively improving the continuity and efficiency of the punching process. Driven by the fourth lifting component, the punching part moves downwards along the arranged through holes, penetrating the back film to complete the punching. Avoiding the through holes provides downward extension space for the punching part, reducing rigid collisions with the mounting base during downward movement. This protects the punching cutting edge and ensures smooth completion of the punching operation, allowing the punching process to be seamlessly integrated into the film cutting process without the need for a separate punching station, thus shortening the overall process route.
[0022] Optionally, the bottom of the mounting base is detachably equipped with a collection frame corresponding to the clearance through hole; the side wall of the mounting base is provided with a mounting groove, and the collection frame has a mounting guide rail that cooperates with the mounting groove; the mounting groove is provided with a locking structure for locking the mounting guide rail; the locking structure includes a ball-head spring plunger, and the mounting guide rail is provided with a locking groove that cooperates with the ball-head spring plunger.
[0023] By adopting the above technical solution, a collection frame corresponding to the clearance through hole can be detachably installed at the bottom of the mounting base. Waste generated during punching falls into the collection frame through the clearance through hole for centralized collection, reducing waste from scattering into the equipment or production environment, maintaining the cleanliness of the surrounding environment, and facilitating waste cleaning and collection. The collection frame is slidably installed via the cooperation of the mounting guide rail and the mounting slide, making it easy to install and remove, allowing operators to quickly clean or replace the collection frame during equipment shutdown maintenance. The locking structure within the mounting slide utilizes the engagement of a ball-head spring plunger and a locking groove to automatically lock the collection frame after it is pushed into place, reducing the probability of accidental slippage or displacement of the collection frame due to equipment vibration.
[0024] In summary, this application includes at least one of the following beneficial technical effects: A back film coating device includes a film cutting mechanism for cutting the back film, an air flotation platform for receiving the cut back film, a first drive mechanism for moving the air flotation platform to facilitate the transfer of the back film, a conveyor belt mechanism for transporting photovoltaic panels to the underside of the coating mechanism, a positioning mechanism for positioning the photovoltaic panels to ensure accurate coating position, a coating suction cup for adsorbing the back film and pressing the back film onto the photovoltaic panel under the drive of a first lifting component, and a spot welding assembly for spot welding the edges of the photovoltaic panel to fix the back film to the photovoltaic panel, thereby improving coating quality and efficiency. By setting an air flotation structure on the air flotation platform, a uniform and stable air cushion layer can be formed between the back membrane and the placement area. This air cushion layer keeps the back membrane in a suspended state, thereby greatly reducing the friction force on the back membrane when it moves and adjusts its position on the air flotation platform. In addition, when the fan equipment draws air through the second air hole, it can firmly attach the back membrane to the surface of the air flotation platform, so that the back membrane remains stable in position and is not prone to shifting or deviating during the overall movement of the air flotation platform. By setting a phase change element between the soldering head and the heating element of the spot welding body, the temperature of the soldering head can be maintained within a stable working range, reducing the occurrence of large temperature fluctuations in the soldering head; and a ball joint connected to the end of the soldering head is set at the output end of the second lifting component, allowing the spot welding body to swing slightly around the center of the ball joint with multiple degrees of freedom, automatically adjusting the contact posture between the soldering head and the edge of the photovoltaic panel, ensuring that the soldering head and the welding point are fully in contact. Attached Figure Description
[0025] Figure 1 This is a schematic diagram of the structure of a backing film coating device according to an embodiment of this application.
[0026] Figure 2 This is a schematic diagram of the top of the back film coating device in an embodiment of this application.
[0027] Figure 3 This is a schematic diagram of the punching assembly in the embodiments of this application.
[0028] Figure 4 This is an exploded view of the punching assembly in an embodiment of this application.
[0029] Figure 5 This is a cross-sectional schematic diagram of the air flotation platform in an embodiment of this application.
[0030] Figure 6 This is a schematic diagram of the coating mechanism in an embodiment of this application.
[0031] Figure 7 This is a schematic diagram of the structure of the first lifting component in the embodiments of this application.
[0032] Figure 8 This is a cross-sectional schematic diagram of the ball joint in an embodiment of this application.
[0033] Figure 9 This is a cross-sectional schematic diagram of the spot welding body in an embodiment of this application.
[0034] Figure 10 This is a schematic diagram of the positioning mechanism in the embodiments of this application.
[0035] Figure 11 This is a schematic diagram of the structure of the first positioning component in the embodiments of this application.
[0036] Explanation of reference numerals in the attached drawings: 1. Frame; 2. Film cutting mechanism; 21. Feeding assembly; 211. Guide roller group; 22. Correction assembly; 221. Correction sensor; 222. Correction actuator; 23. Gripping assembly; 231. Mounting rod; 232. Pneumatic gripper; 24. Second drive mechanism; 241. First guide rail; 25. Punching assembly; 251. Mounting base; 2511. Clearance slot; 2512. Arrangement through hole ; 2513, Clearance through hole; 2514, Mounting slide; 2515, Ball head spring plunger; 252, Punched part; 253, Fourth lifting part; 254, Collection frame; 2541, Mounting guide rail; 2542, Locking groove; 26, Cutting blade; 27, Third lifting part; 28, Positioning roller group; 281, Positioning roller; 3, Coating mechanism; 31, Coating suction cup; 311, Mounting bracket; 3111, Mounting crossbeam; 3 12. Adsorption plate; 32. First lifting component; 33. Spot welding assembly; 331. Spot welding body; 3311. Outer shell; 3312. Soldering head; 3313. Heating element; 3314. Heat insulation sleeve; 3315. Phase change element; 332. Second lifting component; 333. Fixing base; 334. Spherical frame; 335. Ball joint; 34. Adjustment mechanism; 341. First lead screw; 342. Second lead screw; 343. 4. Dual-head motor; 5. Air-floating platform; 6. Air chamber; 7. First air hole; 8. Second air hole; 9. First drive mechanism; 10. Second guide rail; 11. Conveyor belt mechanism; 12. Positioning mechanism; 13. First positioning component; 14. Abutting crossbar; 15. First drive component; 16. Second drive component; 27. Second positioning component; 18. Positioning push rod; 19. Positioning ring block; 20. Third drive component. Detailed Implementation
[0037] The following is in conjunction with the appendix Figure 1-11 This application will be described in further detail.
[0038] This application discloses a backing film coating device. (Refer to...) Figure 1 and Figure 2The back film coating equipment includes a frame 1, a film cutting mechanism 2 mounted on the frame 1, a coating mechanism 3 mounted on the frame 1, an air-floating platform 4 slidably mounted on the frame 1 and located on the output side of the film cutting mechanism 2, a first drive mechanism 5 for driving the air-floating platform 4 to move, a conveyor belt mechanism 6 located below the air-floating platform 4, and a positioning mechanism 7 for adjusting the position of the photovoltaic panel. The air-floating platform 4 receives the back film output after cutting by the film cutting mechanism 2, and the conveyor belt mechanism 6 transports the photovoltaic panel to the area below the coating mechanism 3.
[0039] Reference Figure 1 and Figure 2 The frame 1 has an overall frame structure. The film cutting mechanism 2 is installed on one side of the feeding end of the frame 1 and is used to cut the continuous back film into single pieces of the required size. Specifically, the film cutting mechanism 2 includes a feeding assembly 21, a correction assembly 22 for correcting the back film's deviation, a gripping assembly 23 for holding the front edge of the back film, a second drive mechanism 24 for driving the gripping assembly 23 to move, a punching assembly 25 located between the correction assembly 22 and the gripping assembly 23, a cutting blade 26 arranged side by side with the punching assembly 25, and a third lifting component 27 for driving the cutting blade 26 to rise and fall. The feeding assembly 21 includes a guide roller group 211 for guiding the unwinding of the back film. The correction assembly 22 is located downstream of the guide roller group 211 and includes a correction sensor 221 and a correction actuator 222 for detecting the lateral position of the running back film and correcting it in real time to ensure that the back film runs along a set centerline. In this embodiment, the correction actuator 222 is specifically a lead screw linear module.
[0040] Reference Figure 1 and Figure 3 The punching assembly 25 and the cutting blade 26 are arranged sequentially along the transport direction of the back film. The punching assembly 25 includes a mounting base 251 fixed on the frame 1, a punching component 252 movably mounted on the mounting base 251, and a fourth lifting component 253 mounted on the top of the mounting base 251 for driving the punching component 252 to rise and fall. Specifically, the mounting base 251 is a block-shaped metal base body, which is fixedly mounted on the frame 1 by bolts. The mounting base 251 has a through clearance groove 2511 along the transport direction of the back film. The clearance groove 2511 is a rectangular groove, the width and height of which are slightly larger than the width and thickness of the back film, so that the back film can pass smoothly through the clearance groove 2511 during the transfer process.
[0041] Reference Figure 3The top wall of the clearance groove 2511 has a vertically penetrating through hole 2512 for the movable arrangement of the punching part 252. The bottom wall of the clearance groove 2511 has a clearance through hole 2513 coaxially corresponding to the through hole 2512. The punching part 252 is a cylindrical punch with a rectangular punch at its bottom. The punching part 252 is installed at the output shaft end of the fourth lifting member 253. The output shaft of the fourth lifting member 253 passes through the through hole 2512 and can drive the punching part 252 to move up and down to punch the back film located in the clearance groove 2511. During punching, the punching part 252 passes downward through the back film and extends into the clearance through hole 2513. The punched-off waste material is discharged downward through the clearance through hole 2513.
[0042] Reference Figure 3 and Figure 4 The bottom of the mounting base 251 is detachably fitted with a collection frame 254 corresponding to the clearance through hole 2513. The side wall of the mounting base 251 has a mounting groove 2514, which in this embodiment is a T-shaped groove arranged horizontally. The collection frame 254 is a box-shaped structure with an open top, its top opening aligned with the clearance through hole 2513, used to collect waste material generated during punching. The side wall of the collection frame 254 has a mounting guide rail 2541 that mates with the mounting groove 2514. The cross-sectional shape of the mounting guide rail 2541 matches the mounting groove 2514, allowing the collection frame 254 to slide along the mounting groove 2514 into the bottom of the mounting base 251 or be pulled out from the bottom of the mounting base 251. A locking structure for locking the mounting guide rail 2541 is provided within the mounting groove 2514; the locking structure is specifically a ball-head spring plunger 2515. The mounting guide rail 2541 has a locking groove 2542 that mates with the ball spring plunger 2515. When the collection frame 254 is pushed into place along the mounting slide 2514, the plunger ball of the ball spring plunger 2515 is engaged in the locking groove 2542 under the action of elastic force, creating a locking effect and reducing the probability of the collection frame 254 slipping off under the vibration of the equipment. When it is necessary to disassemble the collection frame 254 to clean up waste, the operator pulls the collection frame 254 outward, and the mounting guide rail 2541 can slide out along the mounting slide 2514, achieving convenient disassembly and assembly. In this embodiment, there are two ball spring plungers 2515, which are symmetrically arranged on both sides of the mounting base 251.
[0043] Reference Figure 1 and Figure 2 The cutting blade 26 has a long, straight blade structure with the blade arranged horizontally along the width of the back film. The cutting blade 26 is fixedly installed at the output end of the third lifting component 27. The third lifting component 27 uses a vertically installed drive cylinder, which can drive the cutting blade 26 to move vertically downward to cut the back film from the complete material strip and obtain a single piece of back film of a set size. After the back film is cut, it falls into the downstream air flotation platform 4 and waits to be transferred to the laminating station below the laminating mechanism 3.
[0044] Reference Figure 2 A positioning roller group 28 is also provided between the punching assembly 25 and the cutting blade 26. The positioning roller group 28 includes two positioning rollers 281 arranged vertically. A gap is left between the roller surfaces of the two positioning rollers 281 for the back film to pass through. After the cutting blade 26 cuts the back film, its front end can still maintain tension and stability, reducing the sagging and displacement of the front end of the back film due to loss of tension after cutting.
[0045] Reference Figure 1 and Figure 2 The gripper assembly 23 is located downstream of the positioning roller group 28. The gripper assembly 23 includes a mounting rod 231 that is slidably mounted on the frame 1 and arranged laterally, and a plurality of pneumatic grippers 232 mounted on the mounting rod 231. The plurality of pneumatic grippers 232 are evenly spaced along the length direction of the mounting rod 231, which can achieve multi-point synchronous clamping of the back film from the front edge of the back film, ensuring the flatness of the back film transfer process.
[0046] Reference Figure 1 and Figure 2 The second drive mechanism 24 is mounted on one side wall of the frame 1. In this embodiment, the second drive mechanism 24 is specifically a rack-and-pinion linear module. The slide of the second drive mechanism 24 is fixedly connected to the mounting rod 231. The frame 1 is provided with a first guide rail 241 on the side opposite to the second drive mechanism 24, which cooperates with the mounting rod 231. The first guide rail 241 has a cuboid structure and extends along the back film conveying direction. The mounting rod 231 has a first groove that cooperates with the first guide rail 241.
[0047] Reference Figure 1 and Figure 2 After gripping the back film, the gripping assembly 23 is driven by the second drive mechanism 24 and has a punching station and a cutting station. When the gripping assembly 23 moves the front end of the back film to the punching station, the punching assembly 25 moves downward and punches an installation hole at the set position of the back film to expose the electrode sheet on the photovoltaic panel. After punching, the second drive mechanism 24 continues to move the back film forward. When the front end of the back film reaches the set cutting position, the gripping assembly 23 stops at the cutting station, and the third lifting component 27 drives the cutting blade 26 to move downward to cut the back film from the whole roll of material, completing the cutting process of a single back film and obtaining a back film with dimensions that meet the current photovoltaic module production requirements.
[0048] Reference Figure 2 and Figure 5The air flotation platform 4 has a flat upper surface placement area, which is a rectangular plane with an area not less than the cutting area of a single backing film, for horizontal laying of the backing film. The air flotation platform 4 has an air flotation structure in the placement area, including an air cavity 41 inside the air flotation platform 4, a first air hole 42 located near the backing film in the placement area and communicating with the air cavity 41, and a second air hole 43 located on the side wall of the air flotation platform 4 and communicating with the air cavity 41. In this embodiment, there are multiple first air holes 42, which are vertically penetrating the upper surface of the air flotation platform 4 to the air cavity 41. These first air holes 42 are arranged in a uniform array in the placement area, equidistantly in a rectangular grid pattern, with a diameter of one to three millimeters and a center-to-center distance of ten to twenty millimeters between adjacent first air holes 42. The second air hole 43 is a through hole vertically opened on the bottom wall of the air flotation platform 4, connecting the air cavity 41 to an external pipeline and, through the pipeline, to an external fan device.
[0049] Reference Figure 2 and Figure 5 The external fan equipment has both a positive pressure state (blowing air into the second air hole 43) and a negative pressure state (drawing air into the second air hole 43). Under positive pressure, the fan blows compressed air into the second air hole 43. After entering the air chamber 41, the gas is evenly blown upwards through multiple first air holes 42, forming a stable air cushion layer between the back membrane and the placement area. This allows the back membrane to suspend above the placement area, enabling the air flotation platform 4 to smoothly transfer the back membrane into position with low friction. After the back membrane is in position, the fan equipment switches to a negative pressure state. Under negative pressure, the fan draws air through the second air hole 43, creating a negative pressure within the air chamber 41. The first air holes 42 generate a downward suction force, firmly adhering the upright back membrane to the surface of the placement area, reducing the probability of displacement during transfer and ensuring that the air flotation platform 4 can stably transport the back membrane to the designated location.
[0050] Reference Figure 1 and Figure 2 In this embodiment, the first drive mechanism 5 is also a rack-and-pinion linear module. The first drive mechanism 5 is installed below the first guide rail 241, and the slide of the first drive mechanism 5 is fixedly connected to the sliding seat on the side wall of the air flotation platform 4. The second drive mechanism 24 is installed below a second guide rail 51 that cooperates with the air flotation platform 4, and the air flotation platform 4 has a second sliding groove that cooperates with the second guide rail 51. The first drive mechanism 5 drives the air flotation platform 4 to slide as a whole along the back film transport direction, and transfers the air flotation platform 4 together with the cut back film to the laminating station directly below the laminating mechanism 3.
[0051] Reference Figure 2 and Figure 6The coating mechanism 3 includes a coating suction cup 31, a first lifting member 32 for driving the lifting and lowering of the coating suction cup 31, and a spot welding assembly 33 mounted on the coating suction cup 31 for spot welding the edges of the photovoltaic panel. The coating suction cup 31 is used to adsorb the back film and press it onto the photovoltaic panel. The coating suction cup 31 includes a mounting frame 311 and multiple adsorption disks 312 mounted on the bottom of the mounting frame 311 and connected to a vacuum generator. In this embodiment, there are four adsorption disks 312, located at the four corners of the bottom of the mounting frame 311, to ensure uniform and stable adsorption of the entire back film.
[0052] Reference Figure 2 and Figure 6 In this embodiment, the first lifting component 32 is specifically a vertically arranged linear screw module. The first lifting component 32 is slidably mounted on the crossbeam of the frame 1. The lifting screw of the first lifting component 32 is arranged vertically, and the vertical mounting section of the mounting frame 311 is connected to the lifting screw through bearings. When the motor of the first lifting component 32 drives the lifting screw to rotate, the lifting screw moves up and down on the crossbeam, thereby causing the mounting frame 311 to drive the film-coating suction cup 31 to rise and fall vertically as a whole, pressing the adsorbed back film downwards onto the surface of the photovoltaic panel.
[0053] Reference Figure 2 and Figure 6 The spot welding assembly 33 is installed on the mounting beam 3111 of the mounting frame 311. In this embodiment, there are two sets of spot welding assemblies 33. The two sets of spot welding assemblies 33 are symmetrically arranged on both sides of the mounting frame 311 along the width direction and located at the edge of the mounting frame. That is, the film-coating suction cup 31 is perpendicular to the conveying direction of the conveyor belt mechanism 6 on both sides. It is used to perform hot melt spot welding to fix the back film at both edges of the photovoltaic panel in the width direction after the film-coating suction cup 31 presses the back film onto the photovoltaic panel.
[0054] Reference Figure 6 and Figure 8 Each spot welding assembly 33 includes a spot welding body 331 and a second lifting member 332 for driving the spot welding body 331 to rise and fall. The second lifting member 332 is fixedly installed on a bracket on the corresponding side of the mounting beam 3111, and its output shaft is arranged in the vertical direction. A fixed seat 333 is provided at the end of the output shaft of the second lifting member 332. A ball frame 334 is provided in the fixed seat 333, and a ball joint 335 is provided in the ball frame 334. The end of the spot welding body 331 away from the soldering head 3312 is connected to the end of the ball joint 335 extending from the fixed seat 333. The ball head portion of the ball joint 335 can swing freely around the center of the ball relative to the ball frame 334 within a certain angle range.
[0055] Reference Figure 6 and Figure 9The spot welding body 331 includes an outer shell 3311, a soldering head 3312 installed inside the outer shell 3311, a heating element 3313 installed inside the outer shell 3311 for heating the soldering head 3312, and a heat insulation sleeve 3314 covering the outside of the heating element 3313. The outer shell 3311 is a cylindrical metal shell, with its end away from the soldering head 3312 connected to a ball joint 335 extending from the fixed base 333, allowing the spot welding body 331 to swing slightly with multiple degrees of freedom relative to the output shaft of the second lifting member 332 to adaptively adjust its downward pressing posture. The soldering head 3312 is installed at the lower opening of the outer shell 3311 and partially extends out of the outer shell 3311, for direct contact with the backsheet and the edge of the photovoltaic panel for hot-melt spot welding. The heating element 3313 is located above the soldering head 3312; in this embodiment, the heating element 3313 is a resistance heating rod.
[0056] Reference Figure 6 and Figure 9 A phase change element 3315 is disposed between the heating element 3313 and the soldering head 3312. The phase change element 3315 includes a phase change shell and a phase change material filled within the phase change shell. The phase change shell is a sealed shell made of thermally conductive metal. When the heating element 3313 heats up, the phase change material absorbs heat and undergoes a solid-liquid phase change. The latent heat of the phase change buffers temperature fluctuations, making the heat transferred to the soldering head 3312 tend to be stable, reducing the probability of sudden temperature rises and falls in the soldering head 3312, thereby ensuring stable spot welding temperature and improving the consistency of solder joint quality.
[0057] Reference Figure 6 and Figure 7 The coating suction cup 31 is also equipped with an adjustment mechanism 34 for driving the relative movement of the two spot welding assemblies 33. The adjustment mechanism 34 includes a first lead screw 341, a second lead screw 342, and a dual-head motor 343. The first lead screw 341 and the second lead screw 342 are coaxially arranged on the mounting beam 3111 of the coating suction cup 31, with opposite thread directions, and their adjacent ends are fixedly connected to the two output shafts of the dual-head motor 343 via couplings. The two spot welding assemblies 33 are slidably mounted on the first lead screw 341 and the second lead screw 342 via lead screw nuts. Specifically, the cylinder of the second lifting member 332 of the spot welding assembly 33 is fixedly connected to the lead screw nut via a nut seat, and the nut seat forms a sliding fit with the mounting beam 3111 on the coating suction cup 31, so that the spot welding assembly 33 can only move along the width direction of the coating suction cup 31 and cannot rotate. When the dual-head motor 343 rotates, the first lead screw 341 and the second lead screw 342 rotate synchronously. Since the threads of the two screws rotate in opposite directions, the two spot welding components 33 move towards or away from each other at the same time, thereby adjusting the distance between them to accommodate photovoltaic panels of different widths.
[0058] Reference Figure 10 and Figure 11 The positioning mechanism 7 includes a first positioning component 71 and a second positioning component 72. The first positioning component 71 is located at the front end of the conveyor belt mechanism 6 below the coating mechanism 3 and is used for longitudinal positioning of the front end of the photovoltaic panel. The first positioning component 71 includes an abutment crossbar 711, a first driving member 712, and a second driving member 713. The abutment crossbar 711 is a cylindrical rod whose length direction is consistent with the width direction of the conveyor belt mechanism 6, and is used to directly abut against the front edge of the photovoltaic panel. The first driving member 712 is a lifting cylinder, fixedly installed on the frame 1, and its piston rod is arranged vertically and connected to the abutment crossbar 711, used to drive the abutment crossbar 711 to rise and fall between a low position and a high position. In the high position, the abutment crossbar 711 protrudes from the upper surface of the conveyor belt mechanism 6, forming a blocking positioning for the photovoltaic panel; in the low position, the abutment crossbar 711 retracts to below the conveying surface of the conveyor belt mechanism 6, allowing the photovoltaic panel to pass. The second driving component 713 is a translation cylinder, whose output end is connected to the cylinder body of the first driving component 712, and is used to drive the entire abutment crossbar 711 to move back and forth along the conveying direction of the conveyor belt mechanism 6.
[0059] Reference Figure 2 and Figure 10 Two sets of second positioning components 72 are provided, located on the left and right sides of the conveyor belt mechanism 6 below the coating mechanism 3 along the width direction, respectively, for laterally clamping and positioning the sides of the photovoltaic panel. Each set of second positioning components 72 includes a positioning push rod 721, a positioning ring block 722, and a third driving component 723. The third driving component 723 is a horizontally arranged cylinder, fixedly mounted on the frame 1 by a crossbeam, and its piston rod is arranged along the width direction of the conveyor belt mechanism 6 and connected to one side of the positioning push rod 721. The positioning ring block 722 is a circular structure, installed at the bottom of the positioning push rod 721, and its sidewall is used to abut against the sidewall of the photovoltaic panel. In this embodiment, there are two positioning ring blocks 722, which are arranged at intervals along the length direction of the positioning push rod 721. Each positioning ring block 722 is made of elastic rubber, which can form a buffer when abutting against the sidewall of the photovoltaic panel, reducing rigid collisions that scratch the side of the photovoltaic panel. After the photovoltaic panel is positioned at the front end by the first positioning component 71, the two third driving components 723 simultaneously push the corresponding positioning push rods 721 to extend towards each other, and the positioning ring blocks 722 on both sides simultaneously apply clamping force to the left and right side walls of the photovoltaic panel, thereby adjusting the photovoltaic panel to the set coating position directly below the coating mechanism 3.
[0060] Combination Figures 1 to 11The implementation principle of a back film coating device according to an embodiment of this application is as follows: First, the film cutting mechanism 2 prepares for back film cutting. The back film is released by the feeding component 21, corrected by the correction component 22, and then conveyed forward. The gripper of the gripping component 23 holds the front edge of the back film, and the lateral drive component drives the gripping component 23 to move forward, so that the back film passes through the punching component 25 and the cutting blade 26 in sequence. When the back film passes through the punching station, the punching component 25 punches mounting holes on the back film to expose the electrode sheets on the photovoltaic panel; then the lateral drive component continues to drive the gripping component 23 to move forward a set distance. At this time, the fan equipment is in a positive pressure state. During the process of the gripper transferring the back film, the back film is suspended above the air flotation platform 4, reducing surface damage caused by friction. When the back film reaches the set cutting length and is located at the cutting station, the third lifting component 27 drives the cutting blade 26 to descend and cut the back film to a fixed length. After cutting, the cutting blade 26 rises and resets, and the gripping assembly 23 continues to hold the back film and move forward until the back film completely falls into the placement area of the air flotation platform 4. The gripping assembly 23 then releases, and the external fan switches to a negative pressure state. The first air hole 42 generates an adsorption force on the back film, fixing it onto the air flotation platform 4. The first drive mechanism 5 drives the air flotation platform 4 to slide along the second guide rail 51, transferring the back film to the laminating station. At the same time, the photovoltaic panel is conveyed by the conveyor belt mechanism 6 to the area below the laminating suction cup 31, and the positioning mechanism 7 positions and aligns the photovoltaic panel. Subsequently, the first lifting component 32 drives the coating suction cup 31 to move the adsorbed back film vertically downward, aligning the back film with the photovoltaic panel and pressing it together, completing the initial bonding of the back film and the photovoltaic panel. Then, the second lifting component 332 drives the spot welding body 331 to extend downward, and the soldering head 3312 contacts the edge of the back film on the photovoltaic panel, performing hot-melt spot welding to fix the edge of the back film to the photovoltaic panel, reducing the probability of slippage or warping of the back film in subsequent processes. During spot welding, the phase change element 3315 buffers and equalizes the temperature of the soldering head 3312, and the ball joint 335 allows the spot welding body 331 to adaptively adjust its downward pressing posture, ensuring full bonding between the soldering head 3312 and the weld point. After spot welding is completed, the spot welding assembly 33 rises and resets, the coating suction cup 31 releases vacuum and rises back, and the conveyor belt mechanism 6 sends the coated photovoltaic panel forward to the next process.
[0061] The above are all preferred embodiments of this application and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.
Claims
1. A backing film coating device, characterized in that, The system includes a frame, a film cutting mechanism mounted on the frame, a film coating mechanism mounted on the frame, an air-floating platform located on the output side of the film cutting mechanism for receiving the back film output after the film cutting mechanism is completed, a first drive mechanism for driving the air-floating platform to move, a conveyor belt mechanism located below the air-floating platform for transporting the photovoltaic panel to the area below the film coating mechanism, and a positioning mechanism for adjusting the position of the photovoltaic panel; the film coating mechanism includes a film coating suction cup, a first lifting member for driving the lifting and lowering of the film coating suction cup, and a mechanism mounted on the film coating suction cup. The system includes a spot welding assembly for spot welding the edges of photovoltaic panels; a film-coating suction cup for adsorbing the back film and pressing it onto the photovoltaic panel; an air flotation platform with a placement area for laying the back film; an air flotation structure in the placement area of the air flotation platform, the air flotation structure including an air cavity inside the air flotation platform, a first air hole in the placement area near the back film and communicating with the air cavity, and a second air hole communicating with the air cavity and connected to an external wind turbine; the first air hole is multiple and arranged in a uniform array. The fan equipment has a positive pressure state and a negative pressure state; under the positive pressure state, the fan equipment blows air into the second air hole, causing the back film to suspend on the air flotation platform; under the negative pressure state, the fan equipment draws air through the second air hole, causing the back film to adhere to the air flotation platform, which is convenient for the film-coating suction cup to adsorb. The spot welding assembly includes a spot welding body and a second lifting component for driving the spot welding body to rise and fall; the spot welding body includes an outer shell, a soldering head installed in the outer shell, a heating element installed in the outer shell for heating the soldering head, and a heat insulation sleeve covering the outside of the heating element; a phase change element is disposed between the heating element and the soldering head; the phase change element includes a phase change housing and a phase change material filled in the phase change housing. The output shaft end of the second lifting component is provided with a fixed seat, the fixed seat is provided with a spherical frame, the spherical frame is provided with a ball joint, and the end of the spot welding body away from the soldering head is connected to the end of the ball joint extending from the fixed seat.
2. The backing film coating equipment according to claim 1, characterized in that, The number of spot welding components is two sets, and the two sets of spot welding components are symmetrically arranged on both sides of the coating suction cup. The coating suction cup is provided with an adjustment mechanism for driving the two spot welding components to move relative to each other. The adjustment mechanism includes a first lead screw, a second lead screw, and a dual-head motor for driving the first lead screw and the second lead screw to rotate synchronously. The two spot welding components are respectively slidably mounted on the first lead screw and the second lead screw. The first lead screw and the second lead screw are coaxially arranged on the mounting beam of the coating suction cup. The threads of the first lead screw and the second lead screw have opposite directions and their close ends are respectively fixedly connected to the two output shafts of the dual-head motor through couplings.
3. The backing film coating equipment according to claim 1, characterized in that, The positioning mechanism includes a first positioning component located at the front end of the conveyor belt mechanism and second positioning components located on both sides of the conveyor belt mechanism; the first positioning component includes an abutting crossbar that abuts against the front edge of the photovoltaic panel, a first driving member for driving the abutting crossbar to rise and fall, and a second driving member for driving the abutting crossbar as a whole to move back and forth along the conveying direction of the conveyor belt mechanism, wherein the abutting crossbar is a cylindrical rod; the second positioning components include a positioning push rod, a positioning ring block installed on the positioning push rod, and a third driving member for driving the positioning push rod to move; the side wall of the positioning ring block abuts against the side wall of the photovoltaic panel.
4. The backing film coating equipment according to claim 1, characterized in that, The film cutting mechanism includes a feeding assembly, a correction assembly for correcting the deviation of the back film, a gripping assembly for clamping the front edge of the back film, a second driving mechanism for driving the gripping assembly to move, a punching assembly located between the correction assembly and the gripping assembly, a cutting blade arranged side by side with the punching assembly, and a third lifting member for driving the cutting blade to rise and fall. The gripping assembly for gripping the back film has a punching station and a cutting station after being driven by the second driving mechanism. The back film is punched by the punching station and then cut by the cutting station.
5. A backing film coating device according to claim 4, characterized in that, The gripper assembly includes a mounting rod slidably mounted on the frame and arranged laterally, and a plurality of pneumatic grippers fixedly mounted on the mounting rod. The plurality of pneumatic grippers are evenly spaced along the length direction of the mounting rod. The second drive mechanism is mounted on an inner side wall of the frame. The slide of the second drive mechanism is fixedly connected to the mounting rod. The frame is provided with a first guide rail on the side opposite to the second drive mechanism, which cooperates with the mounting rod. The first guide rail has a cuboid structure and extends along the back film conveying direction. The mounting rod has a first groove that cooperates with the first guide rail.
6. The backing film coating equipment according to claim 4, characterized in that, The punching assembly includes a mounting base mounted on the frame, a punching part mounted on the mounting base, and a fourth lifting member for driving the punching part to rise and fall. The mounting base has a clearance groove along the movement direction of the back film; the top wall of the clearance groove has an arrangement through hole for the movable arrangement of the punched part; the bottom wall of the clearance groove has an avoidance through hole corresponding to the arrangement through hole.
7. A backing film coating device according to claim 6, characterized in that, The bottom of the mounting base is detachably equipped with a collection frame corresponding to the clearance through hole; the side wall of the mounting base is provided with a mounting groove, and the collection frame has a mounting guide rail that cooperates with the mounting groove; the mounting groove is provided with a locking structure for locking the mounting guide rail; the locking structure includes a ball-head spring plunger, and the mounting guide rail is provided with a locking groove that cooperates with the ball-head spring plunger.