Preheating device and laminating device
By installing heaters, temperature sensors, and material handling doors inside the preheating device during photovoltaic module production, the problems of low preheating efficiency and localized overheating of photovoltaic modules are solved, achieving uniform heating and efficient preheating, and improving lamination efficiency and product quality.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- 通威太阳能(盐城)有限公司
- Filing Date
- 2025-04-24
- Publication Date
- 2026-06-05
AI Technical Summary
In the current photovoltaic module production process, the preheating efficiency of the laminate is low and it is easy to cause problems such as glass curling and cell cracking. Especially when the ambient temperature is low, it requires a long heating time and cannot detect and deal with local overheating in time.
Multiple heaters and temperature sensors are spaced apart along the conveying direction inside the preheating device cavity. Combined with the material handling gate and image acquisition device, uniform heating and real-time temperature detection are achieved. Local overheating problems are dealt with in a timely manner through the material handling gate, and the heating power is adjusted and the alarm is triggered by the controller.
This achieves uniformity and stability in the preheating process, avoids glass curling and cell cracking, improves preheating efficiency and yield of the laminating device, and reduces production costs.
Smart Images
Figure CN224329845U_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of heating technology, and in particular to a preheating device and a laminating device. Background Technology
[0002] In the production process of photovoltaic modules, a laminate consisting of a top sheet, encapsulant layer, solar cells, encapsulant layer, and backsheet needs to be laminated. Traditional laminators include three chambers: a preheating vacuum chamber for preheating and vacuuming, a lamination chamber for lamination and heating, and a cooling chamber for cooling. However, when the laminate is directly transferred to the preheating vacuum chamber for vacuuming and preheating during lamination, the preheating efficiency is low, resulting in a long preheating time. Moreover, prolonged heating of the laminate may lead to thermal stress concentration, causing problems such as glass curling and solar cell cracking. Utility Model Content
[0003] Based on this, this application provides a preheating device and a laminating device that provide stable preheating and are easy to control.
[0004] In a first aspect, this application provides a preheating device, the preheating device comprising:
[0005] A cavity is provided with a conveyor for conveying materials. The cavity has multiple material picking doors, which are spaced apart along the conveying direction of the conveyor.
[0006] A heating mechanism, comprising at least one heater disposed within the cavity, and a plurality of heaters spaced apart along the conveying direction of the conveyor; and,
[0007] The detection mechanism includes multiple temperature sensors disposed within the cavity, the temperature sensors being used to detect the temperature within the cavity.
[0008] In some embodiments, the temperature sensors are respectively disposed at the location of the material receiving gate; or the heaters are respectively disposed at the location of the material receiving gate.
[0009] In some embodiments, the temperature sensor and the heater are arranged alternately along the conveying direction of the conveyor.
[0010] In some embodiments, the detection mechanism further includes an image acquisition device disposed at the feed end of the cavity, the image acquisition device being used to acquire material images on the conveyor to determine the material type.
[0011] In some embodiments, the heater includes an infrared heater.
[0012] In some embodiments, the material handling gate is provided with a handle; and / or,
[0013] The material handling door is equipped with an observation window; and / or,
[0014] The material handling gate further includes a sealing mechanism located at the connection between the material handling gate and the cavity; and / or,
[0015] The material handling gate also includes a heat insulation layer disposed on the surface of the material handling gate.
[0016] In some embodiments, the preheating device further includes an early warning mechanism, which includes multiple alarms, each of which is electrically connected to a corresponding temperature sensor. The alarms are used to receive temperature signals from the temperature sensors and to issue an alarm when the temperature signal exceeds a preset temperature.
[0017] In some embodiments, each of the alarms is respectively installed on the material handling gate, and each of the alarms is electrically connected to the corresponding temperature sensor located at the material handling gate.
[0018] In some embodiments, the preheating device further includes a controller electrically connected to both the temperature sensor and the heater, the controller being used to receive temperature signals from the temperature sensor to control the heating power of the heater.
[0019] In a second aspect, this application provides a lamination apparatus comprising a vacuum preheater, a laminator, and a cooler connected in sequence, and further comprising a preheating device as described in the first aspect, wherein the outlet end of the preheating device is connected to the inlet end of the vacuum preheater.
[0020] Compared with traditional technologies, this application has at least the following beneficial effects:
[0021] This application uses multiple heaters spaced apart along the conveyor's transport direction within the cavity to uniformly heat the material on the conveyor. Temperature sensors are used to monitor the temperature at various points within the cavity, preventing localized overheating. Furthermore, multiple material removal gates are installed on the cavity to remove material from areas of excessively high temperature, preventing problems such as glass curling and battery cell cracking caused by overheating. Moreover, by integrating the preheating device of this application into the lamination unit, the laminated material entering the lamination unit is preheated, reducing the heating requirements of the vacuum preheater in the lamination unit and improving lamination efficiency. Attached Figure Description
[0022] Figure 1 This is a schematic diagram of the external structure of a preheating device provided in one embodiment of this application;
[0023] Figure 2 This is a schematic diagram of the bottom of the cavity of a preheating device provided in one embodiment of this application;
[0024] Figure 3 This is a schematic diagram of the top of the cavity in a preheating device provided in one embodiment of this application.
[0025] Among them, 100-cavity; 110-conveyor; 120-material gate; 121-handle; 200-heating mechanism; 210-heater; 300-detection mechanism; 310-temperature sensor; 320-image acquisition device. Detailed Implementation
[0026] The present application will be further described in detail below with reference to the accompanying drawings, embodiments, and examples. These embodiments and examples are for illustrative purposes only and are not intended to limit the scope of the present application. The purpose of providing these embodiments and examples is to enable a more thorough and comprehensive understanding of the disclosure of the present application. It should also be understood that the present application can be implemented in many different forms and is not limited to the embodiments and examples described herein. Those skilled in the art can make various modifications or alterations without departing from the spirit of the present application, and the equivalent forms obtained also fall within the protection scope of the present application. Furthermore, numerous specific details are set forth in the following description to provide a fuller understanding of the present application. It should be understood that the present application can be implemented without one or more of these details.
[0027] It should be understood that the terms "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", and "outer" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.
[0028] In the description of this application, unless otherwise expressly specified and limited, the terms "connected," "linked," "fixed," and "set" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the meaning of the above terms in this application according to the specific circumstances.
[0029] In this application, "optionally," "optionally," and "optional" mean that something is optional, that is, it means that it is selected from either "with" or "without." If there are multiple "optional" entries in a technical solution, unless otherwise specified, and there are no contradictions or mutual constraints, each "optional" entry shall be independent.
[0030] In this application, the technical features described in an open-ended manner include both closed technical solutions consisting of the listed features and open technical solutions that include the listed features.
[0031] In this application, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or quantity, nor should they be construed as implicitly indicating the importance or quantity of the indicated technical features. Moreover, "first," "second," etc., serve only as a non-exhaustive enumeration and should be understood not to constitute a closed limitation on quantity.
[0032] All references to this application are incorporated herein by reference as if each document were individually incorporated herein by reference. Unless they conflict with the purpose and / or technical solution of this application, all cited references are incorporated herein by reference in their entirety and for all purposes. When references are cited in this application, the definitions of relevant technical features, terms, nouns, phrases, etc., are also incorporated herein by reference. Examples and preferred embodiments of the cited technical features may also be incorporated herein by reference, but only to the extent that they enable the implementation of this application. It should be understood that when the cited content conflicts with the description in this application, this application shall prevail or modifications shall be made adaptably to the description in this application.
[0033] In traditional technologies, to improve the preheating efficiency of lamination equipment, the vacuum preheater is typically optimized. This involves adjusting preheating time and temperature parameters to reduce preheating time and minimize issues like glass warping and cell cracking. However, due to the structure of the vacuum preheater, it's difficult to simultaneously improve preheating efficiency and reduce the risk of glass warping and cell cracking. This is especially true at lower ambient temperatures, where the laminate requires longer preheating times, increasing the risk of localized overheating. Even if localized overheating is detected in the vacuum preheater, the overheated areas cannot be inspected after lamination is complete, impacting product yield.
[0034] Based on this, the first aspect of this application provides a preheating device, such as... Figure 1 , Figure 2 and Figure 3 As shown, the preheating device includes a cavity 100, a heating mechanism 200, and a detection mechanism 300.
[0035] The cavity 100 includes a conveyor 110 for conveying materials, and multiple material handling doors 120 are spaced apart along the conveying direction of the conveyor 110. The heating mechanism 200 includes at least one heater 210 disposed within the cavity 100, with multiple heaters 210 spaced apart along the conveying direction of the conveyor 110. The detection mechanism 300 includes multiple temperature sensors 310 disposed within the cavity 100 for detecting the temperature within the cavity 100.
[0036] This application provides uniform heating of the material on the conveyor 110 by arranging multiple heaters 210 at intervals along the conveying direction of the conveyor 110 within the cavity 100. Furthermore, a temperature sensor 310 detects the temperature at various points within the cavity 100, preventing localized overheating. Additionally, multiple material removal gates 120 are provided on the cavity 100, allowing material located in areas of excessively high temperature to be removed, thus preventing problems such as glass curling and battery cell cracking caused by overheating.
[0037] Understandably, when a temperature sensor 310 detects a temperature higher than a preset temperature, the material handling gate 120 located near that temperature sensor 310 can be opened to observe whether the material at that location is affected by overheating. If there is no significant change, the heating power of the heater 210 can be adjusted to reduce the heating temperature in that area. If adjusting the heating power of the heater 210 still fails to reduce the temperature, the material can be removed through the material handling gate 120 and placed back into the cavity 100 for preheating once the temperature has dropped below the preset temperature. This application, by setting the material handling gate 120, facilitates the handling of materials in various locations within the cavity 100, thereby reducing subsequent processing of defective products and lowering costs.
[0038] In some embodiments, temperature sensors 310 are respectively disposed at the locations of the material handling gate 120. In this application, temperature sensors 310 are disposed at the material handling gate 120, that is, temperature sensors 310 detect the temperature of the area where the material handling gate 120 is located. When the temperature sensor 310 detects an abnormal temperature, the material handling gate 120 can be opened accurately based on the location of the temperature sensor 310, thereby achieving precise positioning of the abnormal temperature area.
[0039] In some embodiments, heaters 210 are respectively disposed at the locations of the material dispensing gate 120. In this application, the heaters 210 are disposed at the locations of the material dispensing gate 120 to facilitate the maintenance of the heaters 210 and to facilitate the identification of the locations of heaters 210 with excessive heating power. In turn, the heating status of the material at that location can be easily observed through the material dispensing gate 120 to avoid problems caused by prolonged heating of the material.
[0040] In some embodiments, such as Figure 3 As shown, temperature sensors 310 and heaters 210 are arranged alternately along the conveying direction of conveyor 110. This application uses alternating arrangements of temperature sensors 310 and heaters 210. Temperature sensors 310 can detect the heating areas of each heater 210 within the cavity 100, thereby adjusting the heating power of the heaters 210 based on the heating temperature distribution detected by the temperature sensors 310. This effectively ensures a uniform and stable heating temperature within the cavity 100, avoids localized overheating, and improves preheating quality and efficiency.
[0041] In some embodiments, such as Figure 1 and Figure 2 As shown, the detection mechanism 300 also includes an image acquisition device 320 disposed at the feeding end of the cavity 100. The image acquisition device 320 is used to acquire images of the material on the conveyor 110 to determine the material type. Optionally, the image acquisition device 320 can be a CCD camera, etc. This application determines the material type by setting the image acquisition device 320 to photograph the material on the conveyor 110. Different preheating methods can be selected according to different material types. For example, for photovoltaic module laminates of different specifications, different preheating temperatures and times can be preset.
[0042] In some embodiments, the heater 210 includes an infrared heater 210. This application selects an infrared heater 210, which not only provides accurate temperature control and uniform heating, but also has a certain degree of penetration, resulting in a good heating effect for photovoltaic module laminates.
[0043] In some embodiments, such as Figure 1 and Figure 2 As shown, a handle 121 is provided on the material handling gate 120. Optionally, the handle 121 is made of heat-insulating material. This application facilitates the opening and closing of the material handling gate 120 by providing a handle 121 on the material handling gate 120.
[0044] In some embodiments, an observation window is provided on the material handling door 120. By providing an observation window, this application allows observation of the interior of the cavity 100 without opening the material handling door 120, thereby reducing the impact of temperature fluctuations inside the cavity 100 caused by opening the material handling door 120.
[0045] It is understood that the observation window in this application is located on the material handling gate 120, which is sufficient to facilitate observation of the material on the conveyor 110. For example, the observation window may be located in the center of the material handling gate 120 or near the material.
[0046] Optionally, a baffle is slidably installed at the observation window. By installing the baffle, this application can reduce heat loss at the observation window.
[0047] In some embodiments, the material handling gate 120 further includes a sealing mechanism located at the connection between the material handling gate 120 and the cavity 100. For example, the sealing structure may be a heat-insulating sealing strip.
[0048] It is understood that the material handling door can be made of heat-insulating material. In some embodiments, the material handling door 120 further includes a heat-insulating layer disposed on the surface of the material handling door 120. For example, the heat-insulating material can be ceramic fiber or glass wool, etc.
[0049] In some embodiments, the preheating device further includes an early warning mechanism (not shown in the figure). The early warning mechanism includes multiple alarms, each electrically connected to a temperature sensor 310. The alarms receive temperature signals from the temperature sensors 310 and issue an alarm when the temperature signal exceeds a preset temperature. For example, the alarms could be audible and visual alarms. In this application, the alarms receive signals from the temperature sensors 310. The alarms judge the temperature signal; if it exceeds the preset temperature, the corresponding alarm issues an alarm, and the location of the temperature anomaly is determined based on the location of the temperature sensor 310 corresponding to the alarm.
[0050] In some embodiments, each alarm is respectively installed on the material handling gate 120, and each alarm is electrically connected to the corresponding temperature sensor 310 located at the material handling gate 120. This application configures the positions and connections of the alarms as described above, and determines the material handling gate 120 where the temperature abnormality occurs based on the alarm signal, thereby achieving rapid and accurate location of the temperature abnormality.
[0051] It is understood that in this application, the alarm is installed on the material handling gate 120, and its function is sufficient to indicate the location. For example, the alarm can be installed at the center of the material handling gate 120.
[0052] In some embodiments, the preheating device further includes a controller (not shown in the figure), which is electrically connected to the temperature sensor 310 and the heater 210 respectively. The controller is used to receive the temperature signal from the temperature sensor 310 to control the heating power of the heater 210. This application utilizes the controller to receive the temperature signal from the temperature sensor 310 and adjust the heating power of the heater 210 accordingly, thereby regulating the temperature distribution within the cavity 100 in real time and ensuring temperature consistency and stability within the cavity 100. For example, based on a PID (proportional-integral-derivative) temperature control algorithm, the power output of the heater 210 is dynamically adjusted in real time according to the actual temperature feedback from the temperature sensor 310.
[0053] In some embodiments, a positioner is also provided inside the cavity 100 to determine the position of the material on the conveyor 110, so that the material is all within the heating area of the heater 210. For example, the positioner can be a photoelectric sensor that detects the position of an object by emitting an infrared beam. When the object passes through the beam, the beam is blocked, and the sensor outputs a signal.
[0054] In some embodiments, the conveyor 110 may be a conveyor belt.
[0055] The second aspect of this application provides a lamination apparatus, which includes a vacuum preheater, a laminator and a cooler connected in sequence. The lamination apparatus also includes a preheating device as described in the first aspect, with the outlet end of the preheating device connected to the inlet end of the vacuum preheater.
[0056] This application incorporates a preheating device at the feed end of the laminating apparatus to preheat the laminates entering the apparatus. The laminates reach the preheated temperature before entering the vacuum preheater, reducing the heating requirements of the vacuum preheater in the laminating apparatus and improving lamination efficiency and yield. Furthermore, by optimizing the preheating process of the laminates, this application effectively improves energy utilization, thereby reducing production costs.
[0057] Exemplarily, a method for laminating a laminate using the above-described laminating apparatus is provided, comprising the following steps:
[0058] S1. The laminate is transported into the cavity 100 using the conveyor 110. After the position of the laminate is determined, the heater 210 is turned on for preheating.
[0059] S2. The temperature inside the cavity 100 is detected by the temperature sensor 310. When the temperature at a certain point inside the cavity 100 is relatively low, the heating power of the heater 210 at the lower temperature is adjusted by the controller to raise the temperature.
[0060] S3. When a relatively high temperature is detected at a certain point within the cavity 100, the controller adjusts the heating power of the heater 210 at the higher temperature point to lower the temperature. Simultaneously, an alarm signal is emitted, and the operator uses the observation window to determine the condition of the laminated material within the cavity 100 based on the alarm's location. If the temperature remains abnormal after adjusting the heater 210, the material removal door 120 is opened to remove the laminated material from that area, and it is then placed back into the cavity 100 once the required temperature is reached.
[0061] S4. The laminated body, after being preheated by the preheating device, is directly fed into the vacuum preheater. After vacuuming and reheating, the laminated body is transferred to the laminator for lamination. After lamination, it enters the cooling device and is cooled down to complete the lamination of the laminated body.
[0062] In summary, this application provides uniform heating of the material on the conveyor 110 by arranging multiple heaters 210 at intervals along the conveying direction of the conveyor 110 within the cavity 100. Furthermore, temperature sensors 310 can detect the temperature at various points within the cavity 100, preventing localized overheating. Additionally, multiple material removal gates 120 are provided on the cavity 100, allowing material located in areas of excessively high temperature to be removed, preventing problems such as glass curling and battery cell cracking caused by overheating. Moreover, by integrating the preheating device of this application into the laminating device, the laminated material entering the laminating device is preheated, reducing the heating requirements of the vacuum preheater in the laminating device and improving lamination efficiency.
[0063] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.
[0064] The above embodiments are merely illustrative of several implementation methods of this application, and their descriptions are relatively specific and detailed, but they should not be construed as limiting the scope of the application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this application should be determined by the appended claims.
Claims
1. A preheating device, characterized in that, The preheating device includes: A cavity (100) is provided with a conveyor (110) inside the cavity (100). The conveyor (110) is used to convey materials. The cavity (100) is provided with a plurality of material picking doors (120). The plurality of material picking doors (120) are spaced apart along the conveying direction of the conveyor (110). A heating mechanism (200) includes at least one heater (210) disposed within the cavity (100), and a plurality of heaters (210) are spaced apart along the conveying direction of the conveyor (110); and, The detection mechanism (300) includes a plurality of temperature sensors (310) disposed in the cavity (100), the temperature sensors (310) being used to detect the temperature inside the cavity (100).
2. The preheating device as described in claim 1, characterized in that, The temperature sensors (310) are respectively located at the location of the material gate (120); or the heaters (210) are respectively located at the location of the material gate (120).
3. The preheating device as described in claim 1, characterized in that, The temperature sensor (310) and the heater (210) are arranged alternately along the conveying direction of the conveyor (110).
4. The preheating device as described in claim 1, characterized in that, The detection mechanism (300) also includes an image acquisition device (320) disposed at the feed end of the cavity (100), the image acquisition device (320) being used to acquire material images on the conveyor (110) to determine the material type.
5. The preheating device as described in claim 1, characterized in that, The heater (210) includes an infrared heater (210).
6. The preheating device as described in claim 1, characterized in that, The material handling gate (120) is provided with a handle (121); and / or, The material handling gate (120) is provided with an observation window; and / or, The material handling gate (120) further includes a sealing mechanism located at the connection between the material handling gate (120) and the cavity (100); and / or, The material handling gate (120) also includes a heat insulation layer disposed on the surface of the material handling gate (120).
7. The preheating device according to any one of claims 1-6, characterized in that, The preheating device also includes an early warning mechanism, which includes multiple alarms. Each alarm is electrically connected to the temperature sensor (310). The alarm is used to receive the temperature signal from the temperature sensor (310) and to issue an alarm when the temperature signal is greater than a preset temperature.
8. The preheating device as described in claim 7, characterized in that, Each of the alarms is respectively installed on the material handling gate (120), and each of the alarms is electrically connected to the corresponding temperature sensor (310) located at the material handling gate (120).
9. The preheating device according to any one of claims 1-6, characterized in that, The preheating device also includes a controller, which is electrically connected to the temperature sensor (310) and the heater (210) respectively. The controller is used to receive the temperature signal from the temperature sensor (310) to control the heating power of the heater (210).
10. A lamination apparatus, characterized in that, The lamination device includes a vacuum preheater, a laminator, and a cooler connected in sequence. The lamination device also includes a preheating device as described in any one of claims 1-9, wherein the outlet end of the preheating device is connected to the inlet end of the vacuum preheater.