Photovoltaic glue film forming device
By using auxiliary rollers and printing rollers to perform controlled heating and cooling in the photovoltaic film forming device, the problems of extreme thickness, deterioration of fluidity and high energy consumption during the traditional photovoltaic film forming process are solved, and the problem of extreme thickness of ABA layer is poor, deterioration of fluidity and high energy consumption is achieved. More stable process and more uniform product quality reduce production costs.
Patent Information
- Application Number
- CN202420681378.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-04-03
- Publication Date
- 2025-01-10
- Estimated Expiration
- 2034-04-03
AI Technical Summary
During the molding of traditional photovoltaic films, there are problems such as poor ABA layer thickness, deterioration of fluidity, additive volatility and crosslinking, uneven edge material width, high energy consumption and increased material consumption, which affect product quality and production costs.
Design a photovoltaic adhesive film forming device, including auxiliary rollers and front printing rollers under the extrusion mold, and use a heater and cooler to control the upper and lower surface layers of the adhesive film, and cancel the infrared lamp tube. , the heating temperature is reduced and the cooling section is extended to ensure sufficient cooling of the adhesive film in multiple cooling roller groups.
It effectively reduces the ABA layer thickness difference, improves the edge material width, improves process stability, uniform weight, energy consumption and material consumption, improves structural performance and production process, and reduces cost investment.
Smart Images
Figure CN222328972U_ABST
Abstract
Description
Technical Field
[0001] The utility model belongs to the technical field of photovoltaic adhesive films, and more specifically relates to a photovoltaic adhesive film forming device. Background Art
[0002] The traditional method of making photovoltaic film is extrusion casting. The molten film is extruded through the die at a matching line speed. In order to release stress and control shrinkage, it will be heated by infrared lamps to fully melt and soften and flow naturally, and then rapidly cooled and drawn for calendering. With the increasingly fierce competition in the industry, production cost and product quality are important indicators for enterprises to consider. It has become a trend to shorten the length of the production line and increase the line speed. Higher requirements are placed on heating and cooling. As the temperature rises, the process becomes more difficult and product quality is affected. The disadvantages are as follows:
[0003] Increased thickness tolerance of ABA layer: As the temperature rises, when the molten film is calendered, in order to avoid the film, battery, and glass from slipping during the client process, patterns are engraved on the surface of the cooling roller and the printing roller. During the extrusion process, the uneven pattern on the roller surface and the difference in fluidity of the AB layer material will destroy the interlayer separation of ABA, and the thickness tolerance of the AB layer will increase. In order to meet the customer's minimum requirement for the thickness of the P layer, the overall thickness of the B layer is increased, and the cost of the raw materials of the AB layer is multiples different, resulting in an additional increase in production costs; in addition, the thickness tolerance of the AB layer increases, and product performance will also be affected.
[0004] Poor fluidity: As the line speed increases, the film's residence time in the heating area shortens. In order to control the shrinkage rate, more infrared heat is required. Due to the unevenness of radiation heating, the local temperature is high, resulting in a high ML of the film, that is, the fluidity deteriorates, increasing the difficulty of the process and affecting product quality.
[0005] Volatilization, decomposition and cross-linking of additives: Traditional molds have a hanger-like structure. The molten film is subjected to the pressure in the mold cavity and diffuses and extrude to the bottom of the hanger. The melt at both ends of the hanger stays in the mold longer than the melt in the middle. After being heated by infrared high temperature, some initiators, cross-linking agents, peroxides and internal molecular bonds of organic polymers in the melt are broken or decomposed. In addition, the material characteristics of the film itself are prone to cross-linking at high temperatures, thus affecting product quality.
[0006] Edge material: In the traditional extrusion casting method, the film is extruded from the co-extrusion die, heated by infrared lamps, pulled by printing rollers, and cooled and shaped by extremely cold rollers. In this process, the film will shrink towards the middle on both sides in the width direction. Due to the limited space between the die outlet and the cooling roller, the shrinkage is limited, the overall width is too large, and the edge material width increases after cutting. In addition, the edge material is heated for a long time during the first processing, and the ML value is relatively high, so the fluidity deteriorates. The difficulty of online secondary processing of recycled materials increases. Often, due to the cross-linking of the edge material, the defect of honeycomb-shaped spreads to the entire width, affecting the product quality, thereby affecting the primary and secondary yields.
[0007] Thickness: As the line speed increases, the power of the infrared lamp gradually increases, and the mold is about 100-150mm away from the heater. More heat is radiated to the mold, and the convection of the molten film in the mold changes. The radiation heat fluctuates and is uneven, which will cause the mold opening to change in time. The film thickness will appear irregularly uneven due to the instantaneous change of the mold opening, and the gram weight tolerance will inevitably increase, increasing the consumption of raw materials and the workload of the machine adjusters, and the invisible cost increases.
[0008] Energy consumption: With the competition of line speed, the infrared heating power increases. The greater the heating amount, the greater the heat loss, resulting in energy waste.
[0009] Impact on cooling and printing (embossing) rollers: As the amount of heating increases, the heat radiated to the cooling roller and printing roller increases, and the heat carried by the film itself also increases. The cooling amount of the cooling roller and printing roller must be matched accordingly, otherwise the shrinkage rate of the film will be difficult to control, and the film will adhere to the printing roller and cannot be peeled off freely, which will increase the probability of the roll wrapping stopping production. If it is barely peeled off by the traction of the cooling roller, the peeling line will be uneven, and the film will bulge abnormally on the client side. In addition, the film has not been fully cooled and shaped, and the cooling roller pulls the film, which will stretch the film, resulting in unqualified shrinkage rate of the finished product after cutting. Therefore, a lower temperature is required for the cooling medium of the roller group, and the surface temperature of the roller group increases, which aggravates the aging life and reduces the life. Both of these will increase manufacturing costs.
[0010] There is a technology named "EVA-POE solar photovoltaic film extrusion production line" and the publication number is "CN116408953 A" in the prior art, which discloses an EVA-POE solar photovoltaic film extrusion production line, and relates to the technical field of automated production lines. The present invention includes a screw extruder for extruding raw materials into a viscous state, a cooling and shaping device for shaping the formed film, a traction machine for traction of the formed film, and a winding device for winding the formed film. The discharge end of the screw extruder is connected to a mold for extruding the viscous raw material into a sheet shape; the cooling and shaping device includes a cooling roller mechanism and a tempering roller line body; a moving component is provided below the cooling roller mechanism to move the cooling roller mechanism out from below the mold. The present invention is provided with a screw extruder, a cooling and shaping device, a traction machine and a winding device. The discharge end of the screw extruder is connected to a mold, and the cooling roller mechanism is arranged below the mold to receive the formed film flowing out of the discharge port of the mold. The formed film is automatically wound up to realize full-line automated production. However, this technology does not involve the technical problems and technical solutions of the present application. Utility Model Content
[0011] The technical problem to be solved by the utility model is: in view of the deficiencies in the prior art, a photovoltaic adhesive film forming device is provided which has a simple structure and can reduce the extreme difference in ABA structural adhesive film layer thickness, improve the edge material width, improve process stability, make gram weight uniform, reduce energy consumption and material consumption, and improve slippage, thereby effectively improving structural performance and manufacturing technology and increasing enterprise cost investment.
[0012] To solve the above-mentioned technical problems, the technical solution adopted by the utility model is:
[0013] The utility model discloses a photovoltaic adhesive film forming device. An auxiliary roller and a front printing roller are arranged below an extrusion die. The adhesive film comprises an upper surface layer, an intermediate layer and a lower surface layer. A heater is arranged at the rear side of the front printing roller close to the lower surface layer. A rear printing roller is arranged at the rear of the heater. A cooler is arranged at the rear of the rear printing roller.
[0014] The auxiliary roller is a flat roller or a lightly patterned roller.
[0015] The auxiliary roller is connected to the auxiliary roller lifting frame, the front printing roller is connected to the printing roller lifting frame, and the auxiliary roller lifting frame and the printing roller lifting frame are respectively installed on the device stand.
[0016] The extrusion die is configured to extrude a film, and the upper surface layer, the middle layer and the lower surface layer of the film are configured to flow downward from the lower part of the extrusion die through the auxiliary roller and the front printing roller.
[0017] The cooler comprises a first cooler component and a second cooler component. The first cooler component is close to the upper surface layer, and the second cooler component is close to the lower surface layer.
[0018] A cooling roller group is also arranged at the rear of the cooler.
[0019] The cooling roller group includes a first cooling roller, a second cooling roller, a third cooling roller, a fourth cooling roller, and a fifth cooling roller.
[0020] The heater is configured to keep the lower surface layer at 60±10°C.
[0021] Each cooling roller of the cooling roller group is respectively connected to a cooling roller lifting frame, and each cooling roller lifting frame is respectively installed on the device stand.
[0022] The technical solution of the utility model is adopted, and the working principle and beneficial effects are as follows:
[0023] The photovoltaic adhesive film forming device described in the utility model comprises an upper surface layer, an intermediate layer and a lower surface layer, and is an ABA structure. The photovoltaic adhesive film is formed, and the molten adhesive film is extruded and sags through the extrusion die at a matching linear speed. The sags include an upper surface layer, an intermediate layer and a lower surface layer. The adhesive film naturally cools and shrinks during the sag process, and then passes through the auxiliary roller (auxiliary cooling roller) and the front printing roller. The cooling roller and the front printing roller rapidly cool the adhesive film 2 to pull the printing and stretch it into a shape. The temperature setting of the front printing roller is usually 0-40°C, so that it can just soften the upper surface layer of the adhesive film with an ABA structure, so that the front printing roller can print on one side and peel it off smoothly. The auxiliary roller assists in cooling, printing and peeling. The lower surface layer of the adhesive film is heated on one side by a heater to soften the lower surface layer, so that it is easy to print, cool and peel it off by the rear printing roller. Finally, the upper surface layer and the lower surface layer of the adhesive film are cooled separately by a cooler. Finally, the adhesive film passes through multiple cooling rollers of the cooling roller group and is fully cooled to achieve the purpose of eliminating stress. BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The following is a brief description of the contents and symbols in the drawings of this specification:
[0025] Figure 1 It is a structural schematic diagram of the photovoltaic adhesive film forming device described in the utility model;
[0026] Figure 2 It is a schematic diagram of the structure of the photovoltaic adhesive film before molding;
[0027] Figure 3 It is a schematic structural diagram of a photovoltaic adhesive film after being formed by the photovoltaic adhesive film forming device described in the utility model;
[0028] The markings in the accompanying drawings are respectively: 1, extrusion die; 2, film; 3, auxiliary roller; 4, front printing roller; 5, heater; 6, rear printing roller; 7, cooler; 8, first cooling roller; 9, second cooling roller; 10, third cooling roller; 11, fourth cooling roller; 12, fifth cooling roller; 13, first component of cooler; 14, second component of cooler; 15, device stand; 16, auxiliary roller lifting frame; 17, printing roller lifting frame; A1, upper surface layer; B, middle layer; A2, lower surface layer. DETAILED DESCRIPTION
[0029] The following is a detailed description of the embodiments of the present invention, such as the shapes, structures, positions and connection relationships of the components involved, the functions and working principles of the components, etc., by referring to the accompanying drawings:
[0030] As attached Figure 1 -Attached Figure 3 As shown, the utility model is a photovoltaic adhesive film forming device, an auxiliary roller 3 and a front printing roller 4 are arranged below the extrusion die 1, the adhesive film 2 includes an upper surface layer A1, an intermediate layer B, and a lower surface layer A2, a heater 5 is arranged near the lower surface layer A2 on the rear side of the front printing roller 4, a rear printing roller 6 is arranged behind the heater 5, and a cooler 7 is arranged behind the rear printing roller 6. The above structure proposes an improved technical solution to address the deficiencies in the prior art. The adhesive film 2 includes an upper surface layer A1, an intermediate layer B, and a lower surface layer A2, which is an ABA structure. Photovoltaic adhesive film is formed, and the molten adhesive film is extruded and spun through the extrusion die 1 at a matching linear speed. The spun adhesive film 2 includes an upper surface layer A1, an intermediate layer B, and a lower surface layer A2. The adhesive film 2 naturally cools and shrinks during the spun process, and then passes through the auxiliary roller (auxiliary cooling roller) 3 and the front printing roller 4. The cooling roller 3 and the front printing roller 4 rapidly cool the adhesive film 2 for pulling and printing and stretching. The temperature setting of the front printing roller 4 is usually 0-40°C, so that it can just soften the upper surface layer A1 of the adhesive film 2 with an ABA structure, and realize single-sided printing by the front printing roller 4 and smooth peeling. The auxiliary roller 3 assists in cooling, printing, and peeling. The lower surface layer A2 of the adhesive film 2 is heated on one side by the heater 5 to soften the lower surface layer A2, which is convenient for printing, cooling and peeling by the rear printing roller 6. Finally, the upper surface layer A1 and the lower surface layer A2 of the adhesive film 2 are cooled separately by the cooler 7. Finally, the adhesive film 2 passes through multiple cooling rollers of the cooling roller group 14 and is fully cooled to achieve the purpose of eliminating stress. The photovoltaic adhesive film forming device described in the utility model has a simple structure, can reduce the extreme difference in ABA structure adhesive film layer thickness, improve the edge material width, improve process stability, make gram weight uniform, reduce energy consumption and material consumption, and improve slippage, thereby effectively improving structural performance and production technology and increasing enterprise cost investment.
[0031] The auxiliary roller 3 is a flat roller or a light pattern roller. The above structure sets the auxiliary roller surface as needed. When the auxiliary roller is a flat roller, it plays a role of auxiliary cooling and peeling. When the auxiliary roller 3 is a light pattern roller, it can play a role of auxiliary cooling, printing, and peeling.
[0032] The auxiliary roller 3 is connected to the auxiliary roller lifting frame 16, the front printing roller 4 is connected to the printing roller lifting frame 17, and the auxiliary roller lifting frame 16 and the printing roller lifting frame 17 are respectively installed on the device stand 15. In the above structure, the auxiliary roller 3 is connected to the auxiliary roller lifting frame 16, and the front printing roller 4 is connected to the printing roller lifting frame 17. Through the control of the auxiliary roller lifting frame 16 and the printing roller lifting frame 17, the auxiliary roller 3 and the front printing roller 4 are adjusted to meet the molding requirements of different film products.
[0033] The extrusion die 1 is configured to extrude a film 2, and the upper surface layer A1, the middle layer B, and the lower surface layer A2 of the film 2 are configured to flow downward from the lower part of the extrusion die 1 through the auxiliary roller 3 and the front printing roller 4. In the above structure, the molten film is extruded and flows downward through the extrusion die 1 at a matching linear speed, and the flowing film 2 includes the upper surface layer A1, the middle layer B, and the lower surface layer A2. The film 2 naturally cools and shrinks during the flow process, and then passes through the auxiliary roller (auxiliary cooling roller) 3 and the front printing roller 4, and multiple components cooperate to complete the film molding.
[0034] The cooler 7 comprises a first cooler component 13 and a second cooler component 14. The first cooler component 13 is close to the upper surface layer A1, and the second cooler component 14 is close to the lower surface layer A2. With the above structure, the cooler 7 cools the upper surface layer A1 and the lower surface layer A2 of the film 2 respectively, so that both sides of the film are cooled simultaneously, which is convenient for subsequent cooling.
[0035] A cooling roller group is also arranged at the rear of the cooler 7. The cooling roller group includes a first cooling roller 8, a second cooling roller 9, a third cooling roller 10, a fourth cooling roller 11, and a fifth cooling roller 12. In the above structure, the number, spacing, and height of the cooling rollers are set according to the specific needs of molding different film products. Therefore, the molding device has high versatility.
[0036] The heater 5 is configured to keep the lower surface layer A2 at 60±10°C.
[0037] Each cooling roller of the cooling roller group is connected to a cooling roller lifting frame, and each cooling roller lifting frame is installed on the device stand 15. With the above structure, each cooling roller can be adjusted in height through the corresponding cooling roller support frame to meet the use requirements.
[0038] The photovoltaic adhesive film forming device described in the utility model has the following specific advantages:
[0039] Reducing the thickness range of the ABA structure adhesive film: cancel the infrared heating below the extrusion die 1, the temperature of the adhesive film is reduced, and when the auxiliary roller (auxiliary cooling roller) 3 and the front printing roller 4 are cooled and shaped, the lower surface layer A2 and the middle layer B have been shaped, and the upper surface layer A1 is at the critical temperature of 60±10℃ for melting and printing. The front printing roller 4 will not damage the structure of the middle layer B and the lower surface layer A2 during printing. The adhesive film 2 passes through the heater 5, so that the lower surface layer A2 is at the critical temperature of 60±10℃ for melting and printing. The heater 5 only needs to provide a temperature of 80-130℃. At this time, the middle layer B and the upper surface layer A1 are both in a shaped state, and the rear printing roller 6 will not damage the structure of the middle layer B and the upper surface layer A1 during printing. The upper surface layer A1 and the lower surface layer A2 are not squeezed during the printing process, and the patterns of the front printing roller 4 and the rear printing roller 6 are both shallow patterns. The middle layer B has been shaped after coming out of the mold, so the thickness range of the ABA layer can be reduced, and the consumption of raw materials for the B layer is reduced.
[0040] Improve process stability: Due to the "thermosetting" characteristics of photovoltaic film materials, the lower the heating temperature, the more stable the quality, provided that the raw materials are melted and the shrinkage is controlled. The new process eliminates infrared lamps, and the film is not heated before printing once. The volatilization and decomposition of additives are improved, and the vulcanization index is perfectly controlled within the design range. The reliability of the film is improved, and the risk and probability of cross-linking are greatly reduced in the low-temperature process. The distance between the mold outlet and the roller group formed by the auxiliary roller 3 and the front printing roller 4 is extended, and the film 2 is extruded through the extrusion die 1 to vertically flow, and the natural cooling and shrinkage distance are increased. A cooler 7 is added to the cooling section, and the film 2 can be better cooled before and after shaping, and the shrinkage can also be improved.
[0041] Uniform weight: The extrusion die (mold) has its own stable temperature control, and the infrared heating under the die is eliminated to prevent it from being disturbed by external heat. The convection of the molten film inside the die is also stable, and the mold opening is affected by thermal expansion and contraction in a regular manner. The thickness is more uniform, the weight is also uniform, the range is reduced, and cost is saved.
[0042] Energy consumption and material consumption are reduced: the heating temperature of the heater 7 is reduced by about 60%, the power consumption is reduced, and the heat loss is reduced. With the new process, the heat carried by the film 2 after being extruded from the mold 1 is reduced, the cooling amount of the roller group is reduced, and the heat radiation received by the surface of the roller group is reduced, and the aging rate is also reduced. In summary, energy consumption and material consumption will be reduced in different proportions.
[0043] Improve slippage: The traditional film forming method is calendering, and the extrusion process will cause the film to be rough and uneven. On the client side, when the film is laminated with the battery cell and tempered glass, the film will be suspended due to its light weight. The patterns of the front printing roller 4 and the rear printing roller 6 of the new process are shallow and uniform, matching the photovoltaic glass pattern and the velvet surface of the battery cell, so that the concave and convex match and fit compactly.
[0044] In the photovoltaic adhesive film forming device of the utility model, the adhesive film 2 comprises an upper surface layer A1, an intermediate layer B, and a lower surface layer A2, and is an ABA structure. A plurality of components are arranged and the relative positions of the components are controlled. Photovoltaic adhesive film is formed, and the molten adhesive film is extruded and spun through the extrusion die 1 at a matching linear speed. The spun adhesive film 2 includes an upper surface layer A1, an intermediate layer B, and a lower surface layer A2. The adhesive film 2 naturally cools and shrinks during the spun process, and then passes through the auxiliary roller (auxiliary cooling roller) 3 and the front printing roller 4. The cooling roller 3 and the front printing roller 4 rapidly cool the adhesive film 2 for pulling and printing and stretching. The temperature setting of the front printing roller 4 is usually 0-40°C, so that it can just soften the upper surface layer A1 of the adhesive film 2 with an ABA structure, and realize single-sided printing by the front printing roller 4 and smooth peeling. The auxiliary roller 3 assists in cooling, printing, and peeling. The lower surface layer A2 of the adhesive film 2 is heated on one side by the heater 5, and the lower surface layer A2 is softened, which is convenient for printing, cooling and peeling by the rear printing roller 6. The upper surface layer A1 and the lower surface layer A2 of the adhesive film 2 are cooled separately by the cooler 7. The adhesive film 2 passes through multiple cooling rollers of the cooling roller group 14 to be fully cooled and stress is eliminated.
[0045] The above is an exemplary description of the utility model in conjunction with the accompanying drawings. It is obvious that the specific implementation of the utility model is not limited to the above-mentioned method. As long as various improvements are made using the method concept and technical solution of the utility model, or the concept and technical solution of the utility model are directly applied to other occasions without improvement, they are all within the protection scope of the utility model.
Claims
1. A photovoltaic adhesive film forming device, characterized in that: An auxiliary roller (3) and a front printing roller (4) are arranged below the extrusion die (1); the adhesive film (2) comprises an upper surface layer (A1), an intermediate layer (B), and a lower surface layer (A2); a heater (5) is arranged on the rear side of the front printing roller (4) near the lower surface layer (A2); a rear printing roller (6) is arranged behind the heater (5); and a cooler (7) is arranged behind the rear printing roller (6).
2. The photovoltaic adhesive film forming device according to claim 1, characterized in that: The auxiliary roller (3) is a flat roller or a lightly patterned roller.
3. The photovoltaic adhesive film forming device according to claim 1 or 2, characterized in that: The auxiliary roller (3) is connected to the auxiliary roller lifting frame (16), the front printing roller (4) is connected to the printing roller lifting frame (17), and the auxiliary roller lifting frame (16) and the printing roller lifting frame (17) are respectively installed on the device stand (15).
4. The photovoltaic adhesive film forming device according to claim 1, characterized in that: The extrusion die (1) is configured to be capable of extruding a rubber film (2), and the upper surface layer (A1), the middle layer (B), and the lower surface layer (A2) of the rubber film (2) are configured to be capable of flowing downward from the lower part of the extrusion die (1) through the auxiliary roller (3) and the front printing roller (4).
5. The photovoltaic adhesive film forming device according to claim 1 or 2, characterized in that: The cooler (7) comprises a first cooler component (13) and a second cooler component (14), wherein the first cooler component (13) is close to the upper surface layer (A1), and the second cooler component (14) is close to the lower surface layer (A2).
6. The photovoltaic adhesive film forming device according to claim 1 or 2, characterized in that: A cooling roller group is also arranged at the rear of the cooler (7).
7. The photovoltaic adhesive film forming device according to claim 6, characterized in that: The cooling roller group comprises a first cooling roller (8), a second cooling roller (9), a third cooling roller (10), a fourth cooling roller (11), and a fifth cooling roller (12).
8. The photovoltaic adhesive film forming device according to claim 1 or 2, characterized in that: The heater (5) is configured to maintain the lower surface layer (A2) at a temperature of 60±10°C.
9. The photovoltaic adhesive film forming device according to claim 6, characterized in that: Each cooling roller of the cooling roller group is connected to a cooling roller lifting frame, and each cooling roller lifting frame is installed on the device stand (15).