Laminating mechanism and laminating machine

Abstract

The application provides a laminating mechanism and a laminating machine. The laminating mechanism comprises a heating plate, a pressing frame, a pressing plate and a plurality of elastic bearing assemblies. The pressing frame is fixed on the side of the heating plate. The edge of the pressing plate is hung on the pressing frame through the elastic bearing assemblies. The elastic bearing assemblies comprise a supporting block, a first spring and a second spring. The edge of the pressing plate is sealingly connected with the pressing frame. An upper chamber is formed between the pressing plate and the heating plate. An open lower chamber is formed on the lower side of the pressing plate. In the deflated state of the upper chamber, the edge of the pressing plate is supported on the first spring, and a gap exists between the edge of the pressing plate and the upper end of the second spring. In the inflation process of the upper chamber, the edge of the pressing plate is supported by the first spring and the upper end of the second spring. Since the edge of the pressing plate is supported on the pressing frame through the plurality of elastic bearing assemblies, the elastic bearing assemblies can prevent the edge of the pressing plate from being bent and deformed downward during the laminating stage, so that the pressure surge area is avoided at the edge and the corner of the photovoltaic module.

Description

Technical Field

[0001] This application relates to the field of photovoltaic module manufacturing, specifically a lamination mechanism and laminator. Background Technology

[0002] Lamination is a crucial step in the photovoltaic (PV) module manufacturing process, accomplished using a laminator. The laminator comprises several vertically arranged lamination mechanisms, each capable of laminating PV modules. Each lamination mechanism has a lamination chamber and a pressure plate within the chamber, dividing the chamber into an upper chamber (located above the pressure plate) and a lower chamber (located below the pressure plate). First, the PV module is fed into the lower chamber. Then, the laminator is closed, and the PV module is heated to melt the EVA adhesive inside. Simultaneously, a vacuum is created in both the upper and lower chambers, removing air bubbles from the PV module in the lower chamber. Next, the upper chamber is inflated, causing the pressure plate to deform downwards and compress the PV module. Ultimately, the molten EVA adhesive fills the gaps between the solar cells, glass, and backsheet, ensuring a strong bond between the cells, glass, and backsheet, forming a stable PV module structure.

[0003] In most existing laminators, the pressure plates are made of silicone rubber. After the upper chamber is filled with air, the silicone rubber, as a flexible material, is used to press the photovoltaic module downwards. The peripheral area of ​​the silicone rubber that is not in contact with the photovoltaic module is prone to bending and deforming downwards under atmospheric pressure. This creates a pressure surge zone at the edges of the photovoltaic module, causing the adhesive at the edges of the photovoltaic module to be squeezed out, resulting in a lack of adhesive at the edges of the photovoltaic module, which ultimately affects the quality of the photovoltaic module. Utility Model Content

[0004] To address the aforementioned technical problems, this application provides a lamination mechanism, the detailed technical solution of which is as follows:

[0005] A lamination mechanism includes a heating plate, a pressure frame, a pressure plate, and several elastic load-bearing components, wherein:

[0006] The pressure frame is fixedly connected to the periphery of the heating plate;

[0007] The edge of the pressure plate is suspended on the pressure frame by several elastic bearing components. The elastic bearing components include a support block, a first spring and a second spring. The support block is fixedly connected to the pressure frame. The first spring and the second spring are arranged on the support block and located below the edge of the pressure plate. Both of them can extend and retract in the vertical direction.

[0008] The peripheral edge of the pressure plate is sealed to the pressure frame. A sealed upper chamber is formed between the upper side of the pressure plate and the lower side of the heating plate. An open lower chamber is formed on the lower side of the pressure plate. At least one first vent is opened on the side wall of the upper chamber to connect the upper chamber with the outside. At least one second vent is opened on the upper side of the heating plate.

[0009] When the upper chamber is not inflated, the edge of the pressure plate is supported by the upper end of the first spring, and there is a gap between the edge of the pressure plate and the upper end of the second spring. During the inflation of the upper chamber, the pressure plate is pressed down and the edge of the pressure plate is supported by the upper ends of the first spring and the second spring.

[0010] The lamination mechanism provided in this application features a pressure plate whose edges are supported on a frame by several elastic load-bearing components. Therefore, during the lamination stage, the supporting force of the elastic load-bearing components on the edges of the pressure plate prevents the peripheral edges of the pressure plate from bending downwards, thereby avoiding pressure surge zones at the edges and corners of the photovoltaic module and improving the quality of the photovoltaic module.

[0011] Specifically, since the elastic bearing component consists of a first spring and a second spring, and when the upper chamber is not inflated, the edge of the pressure plate is supported by the upper end of the first spring, while a gap exists between it and the second spring. This arrangement produces the following technical effect:

[0012] When the laminator is closed, the upper and lower chambers are simultaneously evacuated. When the heating plate heats the photovoltaic module, the first spring supports the pressure plate, thereby keeping the pressure plate separated from the photovoltaic module and preventing the pressure plate from pressing directly down on the photovoltaic module.

[0013] When the upper chamber is inflated and the pressure plate presses down on the photovoltaic module, the first and second springs work together to elastically support the edge of the pressure plate, thereby preventing the pressure plate from bending and deforming downwards around the periphery, and ultimately preventing the formation of pressure surge zones around the edges of the photovoltaic module.

[0014] In some embodiments, the spring constant of the first spring is smaller than that of the second spring.

[0015] The first spring is mainly used to support the pressure plate when the upper chamber is not inflated. Therefore, the spring constant of the first spring can be set to match the weight of the pressure plate. On the one hand, this can reduce costs, and on the other hand, when the upper chamber is inflated, the pressure plate can descend quickly, thereby improving the efficiency of the operation.

[0016] The second spring is mainly used to support the edge of the pressure plate during the process of inflating the upper chamber and pressing the photovoltaic module downward. Therefore, the elastic coefficient of the second spring needs to be set to match the atmospheric pressure in order to produce the desired support effect.

[0017] In some embodiments, the elastic bearing assembly includes a first guide rod and a second guide rod, one end of the first guide rod being fixed to the support block or pressure plate, and one end of the second guide rod being fixed to the support block or pressure plate; a first spring is sleeved on the outside of the first guide rod; and a second spring is sleeved on the outside of the second guide rod.

[0018] The first guide rod supports and guides the first spring, thereby ensuring the stable extension and retraction of the first spring sleeve in the vertical direction. Similarly, the second guide rod supports and guides the second spring, thereby ensuring the stable extension and retraction of the second spring sleeve in the vertical direction.

[0019] In some embodiments, the lamination mechanism further includes a plurality of elastic support components, which are installed in the pressure plate and are disposed away from the pressing area of ​​the pressure plate. The elastic support components have a support surface extending downward from the lower side of the pressure plate.

[0020] When the upper chamber is inflated and the pressure plate presses down on the photovoltaic module, the elastic support component pushes the pressure plate upward from the corresponding position, thereby preventing the area of ​​the pressure plate that is not in contact with the photovoltaic module from undergoing significant downward bending deformation due to atmospheric pressure, and preventing the formation of pressure surge zones at the corners of the photovoltaic module.

[0021] In some embodiments, the elastic support assembly includes at least one first elastic support unit and at least one second elastic support unit, wherein: the plate body of the pressure plate is provided with mounting holes corresponding to the first elastic support unit and the second elastic support unit; each of the first elastic support unit and the second elastic support unit includes a bushing, a support portion and a third spring, wherein: the bushing is installed in the corresponding mounting hole, the upper end of the bushing includes a first limiting portion, and the first limiting portion is provided with a through hole; the support portion passes through the bushing, the upper end of the support portion includes a second limiting portion limited to the upper side of the through hole, and the lower end of the support portion includes a support step extending downward through the bushing; the third spring is sleeved on the support portion, the upper end of the third spring elastically presses against the first limiting portion of the bushing, and the lower end of the third spring elastically presses against the support step, and the lower end surface of the support step constitutes the support surface of the elastic support assembly.

[0022] For the first and second elastic support units, during the downward pressing of the photovoltaic module by the pressure plate, the lower end face of the support part elastically presses against the lamination mechanism below. The support part moves upward relative to the pressure plate, and the first limiting part of the second limiting part bushing of the support part and the third spring are compressed. After being compressed, the third spring pushes upward against the first limiting part of the bushing, and the upward pushing force is transmitted to the pressure plate, thereby preventing the pressure plate from bending and deforming downward. After lamination of the photovoltaic module is completed and the laminator is opened, the lower end face of the support part disengages from the lamination mechanism below, the third spring loses pressure and rebounds, thereby pushing the support part to move downward relative to the pressure plate and reset, and the second limiting part of the support part re-contacts the pressure plate.

[0023] The elastic support assembly is configured to include at least one first elastic support unit and at least one second elastic support unit. Each first elastic support unit cooperates with each second elastic support unit to push the pressure plate from different positions, which can increase the force application area of ​​the pressure plate and improve the uniformity of force on the pressure plate.

[0024] Furthermore, during the downward compression of the photovoltaic module by the pressure plate, the risk of pressure surge zones forming around the perimeter of the photovoltaic module gradually increases. Therefore, by differentiating the lengths of the springs in the first and second elastic support units, it is possible to achieve the following: initially, when the pressure plate compresses the photovoltaic module, only one of the first and second elastic support units is elastically pressed against the lower lamination mechanism, thus pushing the pressure plate upward with a relatively small initial force. As the pressure plate continues to move downward and compress the photovoltaic module, the other of the first and second elastic support units also elastically presses against the lower lamination mechanism, thus allowing the first and second elastic support units to jointly push the pressure plate upward with a larger second force. This further enhances the support effect of the elastic support components and prevents the formation of pressure surge zones around the perimeter of the photovoltaic module.

[0025] Optionally, the elastic coefficient of the third spring in the first elastic support unit is equal to that of the first spring, and the elastic coefficient of the third spring in the second elastic support unit is equal to that of the second spring.

[0026] This setup ensures that, during the process of the pressure plate pressing down on the photovoltaic module, the supporting forces at each stress point on the edge of the pressure plate are balanced with those at each stress point in the middle, thus keeping the pressure plate horizontal and ensuring the lamination effect.

[0027] In some embodiments, the support portion includes a first support member and a second support member, wherein: the first support member passes through the bushing, the upper end of the first support member forms a second limiting portion, and the first support member is provided with an insertion hole; the second support member is fixedly connected to the first support member through the insertion hole, and a support step is provided at the lower end of the second support member.

[0028] By setting the support part as a split structure consisting of a first support member and a second support member, it is convenient to disassemble and assemble the first elastic support unit and the second elastic support unit.

[0029] In some embodiments, the resilient support assembly further includes a sealing cap that is sealed onto the upper surface of the pressure plate, with a mounting hole located inside the sealing cap.

[0030] By setting a sealing cap, the mounting hole and the upper chamber are sealed and isolated, preventing the upper and lower chambers from being connected through the mounting hole and thus avoiding damage to the sealing of the upper and lower chambers.

[0031] In some embodiments, the lamination mechanism further includes a support body disposed on the upper side of the pressure plate and / or the lower side of the heating plate.

[0032] Before the laminator is closed, when the upper chamber is evacuated, the pressure plate will tend to move upward. The support structure can support the pressure plate and prevent it from moving upward too much and being damaged due to excessive deformation.

[0033] In some embodiments, the laminating mechanism further includes a driving member, a drive shaft, a driven shaft, and a conveyor belt, wherein: the drive shaft is disposed at the first end of the pressure frame and / or the heating plate, the driven shaft is disposed at the second end of the pressure frame and / or the heating plate, the conveyor belt is wound around the drive shaft and the driven shaft, and covers the heating plate, the pressure frame, and the pressure plate; the driving member is disposed on the pressure frame and / or the heating plate and is connected to the drive shaft for transmission, and the driving member is used to drive the drive shaft to rotate so as to drive the conveyor belt to convey.

[0034] The conveyor belt is driven by a drive unit, a drive shaft, and a driven shaft, which automatically transports the photovoltaic modules to be laminated to the predetermined lamination position on the lamination unit and automatically outputs the laminated photovoltaic modules from the lamination mechanism.

[0035] This application also provides a laminator, which includes a top cover, at least two lifting drive mechanisms, and the laminator mechanism described in any one of the above claims, wherein:

[0036] The top cover and n lamination mechanisms are arranged in layers from top to bottom;

[0037] The lifting drive mechanism is configured to drive the top cover and n laminating mechanisms to rise, so that adjacent laminating mechanisms, the top cover and the uppermost laminating mechanism move away from each other to open the laminator; and to drive the top cover and n laminating mechanisms to fall, so that adjacent laminating mechanisms, the top cover and the uppermost laminating mechanism move closer to each other to close the laminator.

[0038] n≥2.

[0039] The laminator provided in this application consists of n laminator mechanisms arranged vertically at intervals. When the n laminator mechanisms are closed simultaneously, any two adjacent laminator mechanisms can laminate the photovoltaic modules between them, thereby improving the lamination efficiency. Attached Figure Description

[0040] Figure 1 This is a three-dimensional structural diagram of the pressure-bearing structure in the embodiments of this application;

[0041] Figure 2 This is a bottom view of the pressure-bearing structure in the embodiments of this application;

[0042] Figure 3 for Figure 2AA section view;

[0043] Figure 4 for Figure 3 A magnified view of a portion of region C;

[0044] Figure 5 for Figure 2 BB cross-sectional view;

[0045] Figure 6 for Figure 5 A magnified view of a portion of region D;

[0046] Figure 7 This is a cross-sectional view of the laminator in an embodiment of this application.

[0047] Figures 1 to 7 Includes:

[0048] Lamination mechanism 10:

[0049] Heating plate 1;

[0050] Pressure frame 2: Upper pressure frame 21, lower pressure frame 22;

[0051] Pressure plate 3;

[0052] Elastic bearing component 4: support block 41, first spring 42, second spring 43, first guide rod 44, second guide rod 45;

[0053] Elastic support assembly 5: First elastic support unit 51, second elastic support unit 52, sealing cap 53, bushing 511, support part 512, third spring 513, first limiting part 514, second limiting part 515, support step 516, first support member 512a, second support member 512b;

[0054] Upper chamber 6;

[0055] Inferior chamber 7;

[0056] Sealing gasket 8;

[0057] Support 9;

[0058] Drive component 110;

[0059] 120mm drive shaft;

[0060] Driven shaft 130. Detailed Implementation

[0061] To make the above-mentioned objects, features, and advantages of this application more apparent and understandable, the application will be further described in detail below with reference to the accompanying drawings and specific embodiments. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with this application. Rather, they are merely examples of apparatuses and methods consistent with some aspects of this application as detailed in the appended claims.

[0062] As described in the background section, most of the press plates in existing laminators are silicone plates. After the upper chamber is filled with air, when the silicone plate, as a flexible material, is used to press the photovoltaic module downwards, the peripheral area of ​​the silicone plate that is not in contact with the photovoltaic module is prone to bending and deforming downwards under atmospheric pressure. This creates a pressure surge zone at the edges of the photovoltaic module, causing the adhesive at the edges of the photovoltaic module to be squeezed out, resulting in a lack of adhesive at the edges of the photovoltaic module, which ultimately affects the quality of the photovoltaic module.

[0063] In view of this, this application provides a lamination mechanism that can prevent the peripheral edges of the pressure plate from bending and deforming downwards, thereby avoiding the formation of pressure surge zones at the edges and corners of the photovoltaic module and improving the quality of the photovoltaic module. Figures 1 to 6 The structure of the lamination mechanism in the embodiments of this application is shown.

[0064] As 1 to Figure 6 As shown, the lamination mechanism 10 of this application includes a heating plate 1, a pressure frame 2, a pressure plate 3, and several elastic bearing components 4, wherein:

[0065] The pressure frame 2 is fixedly connected to the periphery of the heating plate 1.

[0066] The edge of the pressure plate 3 is suspended on the pressure frame 2 by several elastic bearing components 4. The elastic bearing components 4 include a support block 41, a first spring 42 and a second spring 43. The support block 41 is fixedly connected to the pressure frame 2. The first spring 42 and the second spring 43 are arranged on the support block 41 and located below the edge of the pressure plate 3, and both can extend and retract in the vertical direction.

[0067] The peripheral edge of the pressure plate 3 is sealed to the pressure frame 2. In one embodiment, the pressure frame 2 includes an upper pressure frame 21, a lower pressure frame 22, and a locking mechanism. The upper pressure frame 21 is fixedly connected to the periphery of the heating plate 1, and the lower pressure frame 22 is locked to the upper pressure frame 21 by the locking mechanism. Specifically, the upper pressure frame 21 is a quadrilateral frame, arranged along the four edges of the lower surface of the heating plate 1. The lower pressure frame 22 is a quadrilateral frame, arranged below the upper pressure frame 21, with its four sides opposite to the four sides of the upper pressure frame 21. Multiple locking mechanisms at each side lock the upper pressure frame 21 and the lower pressure frame 22 together. The locking mechanism can be any existing locking mechanism such as a quick clamp or a latch. Figure 4As shown, the lamination mechanism 10 of this application also includes a sealing gasket 8, which is a quadrilateral silicone gasket with a hollow center. The outer four edges of the sealing gasket 8 are sealed and clamped between the upper pressure frame 21 and the lower pressure frame 22. The inner four edges of the sealing gasket 8 are pressed and fixed on the pressure plate 3 by a pressure strip. The pressure strip can be a metal strip, which can be fixed on the pressure plate by screws or rivets.

[0068] After being sealed by the sealing gasket 8, a sealed upper chamber 6 is formed between the upper side of the pressure plate 3 and the lower side of the heating plate 1, and an open lower chamber 7 is formed on the lower side of the pressure plate 3. At least one first vent is opened on the side wall of the upper chamber 6 to connect the upper chamber 6 with the outside, and at least one second vent is opened on the upper side of the heating plate 1.

[0069] like Figure 4 As shown, when the upper chamber 6 is not inflated, the edge of the pressure plate 3 is supported by the upper end of the first spring 42, and there is a gap H between the edge of the pressure plate 3 and the upper end of the second spring 43. The natural length of the first spring 42 is greater than the length of the second spring 43.

[0070] During the inflation of the upper chamber 6, the pressure plate 3 is pressed down and the edge of the pressure plate 3 is supported by the upper ends of the first spring 42 and the second spring 43.

[0071] The lamination mechanism 10 of this application can be applied to a laminator, which includes lamination mechanisms 10 arranged in layers from top to bottom for laminating multilayer photovoltaic modules. Its general working process is as follows:

[0072] The laminator is opened, and adjacent lamination mechanisms 10 separate. The upper chamber 6 is evacuated, and the edges of the pressure plates 3 of each lamination mechanism 10 are supported by the upper ends of the first springs 42, with a gap between the edges of the pressure plates 3 and the upper ends of the second springs 43.

[0073] The photovoltaic modules to be laminated are transported to each lamination mechanism 10, meaning that each lamination mechanism 10 carries a photovoltaic module. In addition, a vacuum is drawn into the upper chamber 6 through the first vent of each lamination mechanism 10, causing the pressure plate 3 of each lamination mechanism 10 to move upward to a certain extent, ensuring that the height of the lower chamber 7 of each lamination mechanism 10 is sufficient to accommodate the photovoltaic modules.

[0074] Subsequently, the laminator is closed, causing adjacent lamination mechanisms 10 to overlap. The lower chamber 7 is sealed by the lamination mechanism 10 below it, and the photovoltaic module is located inside the sealed lower chamber 7.

[0075] Next, a vacuum is also created in the lower chamber 7 through the second vent of each lamination mechanism 10. Specifically, the upper chamber 6 of each lamination mechanism 10 is evacuated through its own first vent, while the lower chamber 7 of each lamination mechanism 10 is evacuated through the second vent of the adjacent lamination mechanism 10 below it. Simultaneously, the heating plate 1 of each lamination mechanism 10 heats the photovoltaic module, causing the encapsulant film in the photovoltaic module to melt and air bubbles to be extracted.

[0076] During this process, since both the upper chamber 6 and the lower chamber 7 are in a vacuum state, the force borne by the elastic bearing component 4 is mainly the weight of the pressure plate 3 itself. Therefore, at this time, the edges of the pressure plates 3 of each lamination mechanism 10 are still supported by the upper end of the first spring 42, and there is a gap between the edge of the pressure plate 3 and the upper end of the second spring 43. That is, the elastic support force of the first spring 42 on the pressure plate 3 offsets the weight of the pressure plate 3, thereby maintaining a predetermined gap between the pressure plate 3 and the photovoltaic module, preventing the pressure plate 3 from falling under its own weight and pressing directly onto the photovoltaic module, thus avoiding premature compression of the photovoltaic module and ensuring that the air bubbles in the photovoltaic module are fully extracted.

[0077] Next, the upper chamber 6 stops being evacuated, and the first vent of each lamination mechanism 10 fills the upper chamber 6 with air, while the lower chamber 7 remains evacuated. Since the upper side of the pressure plate 3 is under positive pressure and the lower side is under negative pressure, the pressure plate 3 moves downwards, eventually contacting the photovoltaic module and pressing it downwards to satisfy the physicochemical processes required for photovoltaic module lamination. During this process, the downward movement of the pressure plate 3 contacts and compresses the second spring 43, causing the first spring 42 and the second spring 43 to work together to elastically support the edge of the pressure plate 3, preventing the periphery of the pressure plate 3 from bending downwards and ultimately avoiding the formation of pressure surge zones around the edges of the photovoltaic module. This ensures uniform pressure on the photovoltaic module and improves its quality.

[0078] As can be seen, in the lamination mechanism 10 provided in this application, the edge of the pressure plate 3 is supported on the pressure frame 2 by several elastic bearing components 4. Therefore, during the lamination stage, the supporting force of the elastic bearing components 4 on the edge of the pressure plate 3 can prevent the peripheral edge of the pressure plate 3 from bending and deforming downward, thereby avoiding the formation of pressure surge zones at the periphery and corners of the photovoltaic module and improving the quality of the photovoltaic module.

[0079] Specifically, since the elastic bearing component 4 is composed of a first spring 42 and a second spring 43, and when the upper chamber is not inflated, the edge of the pressure plate 3 is supported by the upper end of the first spring 42, while a gap exists between it and the second spring 43. This arrangement has the following technical effect: when the laminator is closed and the upper chamber 6 and lower chamber 7 are simultaneously evacuated, and the heating plate 1 heats the photovoltaic module, the first spring 42 supports the pressure plate 3, thus keeping the pressure plate 3 separated from the photovoltaic module and preventing the pressure plate 3 from directly pressing down on the photovoltaic module. When the upper chamber 6 is inflated, during the process of the pressure plate 3 pressing down on the photovoltaic module, the first spring 42 and the second spring 43 together elastically support the edge of the pressure plate 3 upwards, thereby preventing the periphery of the pressure plate 3 from bending downwards and ultimately preventing the formation of pressure surge zones around the edges of the photovoltaic module.

[0080] Since the first spring 42 is mainly used to support the pressure plate 3 when the upper chamber 6 is not inflated, preventing the pressure plate from prematurely pressing down on the photovoltaic module, the elastic coefficient of the first spring 42 can be set to match the weight of the pressure plate 3. This reduces costs and allows the pressure plate 3 to descend quickly when the upper chamber 6 is inflated, thus improving work efficiency. The second spring 43 is mainly used to support the edges of the pressure plate 3 during the inflation of the upper chamber 6 and the contact and downward compression of the photovoltaic module by the pressure plate 3, preventing excessive downward deformation of the edges of the pressure plate 3 and avoiding pressure surge zones around the edges of the photovoltaic module. Therefore, the elastic coefficient of the second spring 43 must be set to match atmospheric pressure to achieve the desired support effect.

[0081] For the reasons mentioned above, in some embodiments, the spring constant of the first spring 42 is less than that of the second spring 43.

[0082] like Figure 4 As shown, in some embodiments, the elastic bearing component 4 includes a first guide rod 44 and a second guide rod 45. One end of the first guide rod 44 is fixed to the support block 41 or the pressure plate 3, and one end of the second guide rod 45 is fixed to the support block 41 or the pressure plate 3. A first spring 42 is sleeved on the outside of the first guide rod 44, and a second spring 43 is sleeved on the outside of the second guide rod 45.

[0083] The first guide rod 44 supports and guides the first spring 42, thereby ensuring the stable extension and contraction of the first spring 42 in the vertical direction. Similarly, the second guide rod 45 supports and guides the second spring 43, thereby ensuring the stable extension and contraction of the second spring 43 in the vertical direction.

[0084] Continue to refer to Figures 1 to 6As shown, in some embodiments, the lamination mechanism 10 of this application further includes a plurality of elastic support components 5. The elastic support components 5 are installed in the pressure plate 3, and the elastic support components 5 are disposed away from the pressing area of ​​the pressure plate 3. The elastic support components 5 have a supporting surface extending downward from the lower side of the pressure plate 3. The pressing area refers to the contact area between the pressure plate 3 and the photovoltaic module during the lamination process. For example, Figures 1 to 2 In the embodiment shown, the pressure plate 3 has three pressing areas (as shown by the dotted frame in the figure), and each pressing area can be used to laminate a photovoltaic module.

[0085] When the upper chamber 6 is inflated and the pressure plate 3 is pressing down on the photovoltaic module, the elastic support component 5 pushes the pressure plate 3 upward from the corresponding position, thereby preventing the area of ​​the pressure plate 3 that is not in contact with the photovoltaic module from undergoing significant downward bending deformation due to atmospheric pressure. Ultimately, this prevents the formation of pressure surge zones at the corners of the photovoltaic module, further ensuring the quality of the photovoltaic module.

[0086] In some embodiments, the elastic support component 5 includes at least one first elastic support unit 51 and at least one second elastic support unit 52. For example, Figure 2 , Figure 5 and Figure 6 In the illustrated embodiment, the elastic support assembly 5 includes two first elastic support units 51 and a second elastic support unit 52 located between the two first elastic support units 51. Of course, other numbers of first elastic support units 51 and second elastic support units 52 may also be provided. Figure 2 In the middle, a row of elastic support components 5 is set between two adjacent pressing areas. Each row of elastic support components 5 includes 3 elastic support components 5. The two first elastic support units 51 and one second elastic support unit 52 in each elastic support component 5 are also arranged in a row.

[0087] The pressure plate 3 has mounting holes corresponding to the first elastic support unit 51 and the second elastic support unit 52. Both the first elastic support unit 51 and the second elastic support unit 52 include a bushing 511, a support portion 512, and a third spring 513. The bushing 511 is installed in the corresponding mounting hole, and its upper end includes a first limiting portion 514 with a through hole. The support portion 512 passes through the bushing 511, and its upper end includes a second limiting portion 515 positioned above the through hole. The lower end of the support portion 512 includes a support step 516 extending downwards from the bushing 511.

[0088] The first limiting part 514 is, for example, a sealing plate provided on the port of the bushing 511.

[0089] The third spring 513 is sleeved on the support part 512. Under pressure, the upper end of the third spring 513 elastically presses against the first limiting part 514 of the bushing 511, and the lower end of the third spring 513 elastically presses against the support step 516. The lower end surface of the support step 516 constitutes the support surface of the elastic support assembly 5.

[0090] Taking the first elastic support unit 51 as an example, during the downward pressing of the photovoltaic module by the pressure plate 3, the lower end face of the support part 512 is elastically pressed against the lamination mechanism 10 on the lower side. The support part 512 moves upward relative to the pressure plate 3, and the second limiting part 515 of the support part 512 moves away from the first limiting part 514 of the bushing 511. The third spring 513 is compressed. After being compressed, the third spring 513 pushes upward against the first limiting part 514 of the bushing 511. The upward pushing force is transmitted to the pressure plate 3, thereby preventing the pressure plate 3 from bending and deforming downward.

[0091] After the lamination of the photovoltaic module is completed and the laminator is opened, the lower end face of the support part 512 disengages from the lamination mechanism 10 on the lower side, the third spring 513 loses pressure and rebounds, thereby pushing the support part 512 to move downward relative to the pressure plate 3 to reset, and the second limiting part 515 of the support part 512 re-contacts the pressure plate 3.

[0092] The elastic support assembly 5 is configured to include at least one first elastic support unit 51 and at least one second elastic support unit 52. Each first elastic support unit 51 and each second elastic support unit 52 cooperate to push the pressure plate 3 from different positions, thereby increasing the force application area on the pressure plate 3 and improving the uniformity of force on the pressure plate 3.

[0093] Furthermore, during the downward pressing of the photovoltaic module by the pressure plate 3, the force on the edges of the photovoltaic module increases as the pressure plate 3 presses down, correspondingly increasing the risk of forming a pressure surge zone. Therefore, by differentiating the lengths of the springs in the first elastic support unit 51 and the second elastic support unit 52, the following can be achieved:

[0094] In the initial stage when the pressure plate 3 presses the photovoltaic module downwards, only one of the first elastic support unit 51 and the second elastic support unit 52 is elastically pressed against the lamination mechanism 10 below, thereby pushing the pressure plate 3 upwards with a relatively small first force. As the pressure plate 3 continues to move downwards to contact and press the photovoltaic module, the other of the first elastic support unit 51 and the second elastic support unit 52 is also elastically pressed against the lamination mechanism 10 below. In this way, the first elastic support unit 51 and the second elastic support unit 52 together push the pressure plate 3 upwards with a larger second force, thereby further improving the support effect of the elastic support component 5 and avoiding the formation of pressure surge zones at the edges of the photovoltaic module.

[0095] by Figure 6In the example of the Chinese embodiment, the third spring 513 of the first elastic support unit 51 is longer, while the third spring 513 of the second elastic support unit 52 is shorter. Before the pressure plate presses down on the photovoltaic module, the third spring 513 of the first elastic support unit 51 is already elastically pressed against the first limiting part 514 of the bushing 511, while the third spring 513 of the second elastic support unit 52 has not yet contacted the first limiting part 514 of the bushing 511. Therefore, in the initial stage of the pressure plate 3 pressing down on the photovoltaic module, the first elastic support unit 51 elastically presses against the lamination mechanism 10 on the lower side, and the second elastic support unit 52 does not elastically press against the lamination mechanism 10 on the lower side. Correspondingly, at this time, only the first elastic support unit 51 pushes the pressure plate 3 upward. As the pressure plate 3 continues to press down, the upper end of the third spring 513 of the second elastic support unit 52 presses against the first limiting part 514 of the bushing 511, and the second elastic support unit 52 is elastically pressed against the laminating mechanism 10 on the lower side. Correspondingly, at this time, the first elastic support unit 51 and the second elastic support unit 52 push the pressure plate 3 upward together.

[0096] In some embodiments, the elastic coefficient of the third spring 513 of the first elastic support unit 51 is equal to that of the first spring 42, and the elastic coefficient of the third spring 513 of the second elastic support unit 52 is equal to that of the second spring 43. The third spring 513 of the first elastic support unit 51 may be a spring of the same type as the first spring 42, and the third spring 513 of the second elastic support unit 52 may be a spring of the same type as the second spring 43.

[0097] This configuration ensures that, during the process of the pressure plate 3 pressing down on the photovoltaic module, the supporting forces at the edges of the pressure plate 3 corresponding to the elastic bearing components 4 are balanced with those at the middle of the pressure plate 3 corresponding to the elastic support components 5, thereby keeping the pressure plate 3 horizontal and ensuring the lamination effect.

[0098] like Figure 6 As shown, in some embodiments, the support portion 512 includes a first support member 512a and a second support member 512b, wherein: the first support member 512a passes through the bushing 511, the upper end of the first support member 512a forms a second limiting portion 515, and the first support member 512a is provided with an insertion hole. The second support member 512b is fixedly connected to the first support member 512a through the insertion hole, and a support step 516 is provided at the lower end of the second support member 512b.

[0099] By configuring the support part 512 as a split structure consisting of the first support member 512a and the second support member 512b, it is convenient to assemble and disassemble the first elastic support unit 51 and the second elastic support unit 52.

[0100] The installation process of the first elastic support unit 51 is as follows: First, the bushing 511 is inserted into the mounting hole and fixed in place, for example, by screwing. Then, the first support member 512a is inserted into the bushing 511 from top to bottom. Next, the third spring 513 is fitted onto the first support member 512a from bottom to top. Finally, the second support member 512b is fixedly connected to the first support member 512a through the insertion hole, thus completing the installation of the first elastic support unit 51. Specifically, the first support member 512a includes a horizontal first circular plate and a first column vertically fixed to the center of the lower surface of the first circular plate. The lower end face of the first column has a threaded insertion hole, and the first circular plate serves as the second limiting part 515. The second support member 512b includes a horizontal second circular plate and a second column fixed vertically to the middle of the upper surface of the second circular plate. The second circular plate is the support step 516. The second column has external threads and is locked in the insertion hole of the first column to realize the connection between the first support member 512a and the second support member 512b. In addition, a buffer pad can be attached to the lower surface of the second circular plate to achieve a buffering effect.

[0101] In some embodiments, the bushings 511 of each first elastic support unit 51 and each second elastic support unit 52 are integral structures. Therefore, each first elastic support unit 51 and each second elastic support unit 52 bushing 511 can be installed into the corresponding mounting holes in one go, and then the other components of each first elastic support unit 51 and each second elastic support unit 52 can be installed. Of course, the bushings 511 of each first elastic support unit 51 and each second elastic support unit 52 can also be independent of each other.

[0102] like Figure 6 As shown, in some embodiments, the elastic support assembly 5 further includes a sealing cap 53, which is sealed and mounted on the upper surface of the pressure plate 3, with a mounting hole located inside the sealing cap 53.

[0103] By setting the sealing cap 53, the mounting hole and the upper chamber 6 are sealed and isolated, preventing the upper chamber 6 and the lower chamber 7 from being connected through the mounting hole, which would damage the sealing performance of the upper chamber 6 and the lower chamber 7.

[0104] like Figure 4 and Figure 6 As shown, in some embodiments, the lamination mechanism 10 of this application further includes a support 9, which is arranged on the upper side of the pressure plate 3 and / or the lower side of the heating plate 1.

[0105] Before the laminator is closed, when the upper chamber 6 is evacuated, the pressure plate 3 will tend to move upwards. The support body 9 can support the pressure plate 3 to prevent it from moving upwards excessively and being damaged due to excessive deformation. The support body 9 can be composed of several support tubes or support bars arranged side by side. The support tubes or support bars can be, for example, metal tubes or metal bars.

[0106] In some embodiments, the heating plate 1 includes a plate body and an electromagnetic heating assembly, the electromagnetic heating assembly being disposed inside or on the underside of the plate body. The electromagnetic heating assembly is used to heat the heating plate 1, enabling the heating plate 1 to have heating performance and to heat the photovoltaic module during the lamination process.

[0107] In some embodiments, the pressure plate 3 is a rigid pressure plate such as a metal plate, bakelite board, or polyester fiber board. Using a rigid metal plate, bakelite board, or polyester fiber board as the pressure plate 3 improves the pressure-bearing strength of the pressure plate 3. While ensuring the lamination effect on the photovoltaic module, it further ensures that the peripheral area of ​​the pressure plate 3 that is not in contact with the photovoltaic module will not undergo significant downward bending deformation due to atmospheric pressure during the lamination process.

[0108] like Figure 1 and Figure 2 As shown, in some embodiments, the laminating mechanism 10 of this application further includes a driving member 110, a drive shaft 120, a driven shaft 130, and a conveyor belt (not shown in the figure), wherein: the drive shaft 120 is disposed at the first end of the pressure frame 2 and / or the heating plate 1, the driven shaft 130 is disposed at the second end of the pressure frame 2 and / or the heating plate 1, and the conveyor belt is wound around the drive shaft 120 and the driven shaft 130, and covers the heating plate 1, the pressure frame 2, and the pressure plate 3. The driving member 110 is disposed on the pressure frame 2 and / or the heating plate 1 and is drively connected to the drive shaft 120. The driving member 110 is used to drive the drive shaft 120 to rotate, so as to drive the conveyor belt to convey.

[0109] The conveyor belt is driven by the drive unit 110, the drive shaft 120 and the driven shaft 130, so that the conveyor belt can automatically transport the photovoltaic modules to be laminated to the predetermined lamination position on the lamination mechanism 10, and automatically output the laminated photovoltaic modules from the lamination mechanism 10.

[0110] Based on the same inventive concept, this application also provides a laminator. For example... Figure 7 As shown, the laminator includes a top cover, at least two lifting drive mechanisms, and n laminating mechanisms 10 provided in one embodiment above, wherein:

[0111] The top cover and n lamination mechanisms 10 are arranged in layers from top to bottom.

[0112] The lifting drive mechanism is configured to drive the top cover and n laminating mechanisms 10 to rise, so that adjacent laminating mechanisms 10, the top cover and the uppermost laminating mechanism 10 are moved away from each other to open the laminator; and to drive the top cover and n laminating mechanisms 10 to fall, so that adjacent laminating mechanisms 10, the top cover and the uppermost laminating mechanism 10 are moved closer to each other to close the laminator.

[0113] n≥2.

[0114] The laminator provided in this application consists of n lamination mechanisms 10 arranged vertically at intervals. When the n lamination mechanisms 10 are closed synchronously, any two adjacent lamination mechanisms 10 can laminate the photovoltaic modules between them, thereby improving lamination efficiency. The top cover and lifting drive mechanism in this application can adopt existing structures, so they will not be described in detail here.

[0115] In addition, the conveyor belt of each lamination mechanism 10 can transport the photovoltaic module to the corresponding lamination position, and output the photovoltaic module from the lamination mechanism 10 after lamination is completed.

[0116] This application provides a sufficiently detailed and specific description. Those skilled in the art should understand that the descriptions in the embodiments are merely exemplary, and all changes made without departing from the true spirit and scope of this application should fall within its protection scope. The scope of protection claimed in this application is defined by the claims, not by the above descriptions in the embodiments. Without contradiction, some optional components in one embodiment can also be used in another embodiment, and some preferred structures of the same component in one embodiment are also applicable to another embodiment. Furthermore, there may be slight differences in the wording of the names of certain components in different embodiments; these slight differences will not affect the understanding of the technical solution of the present invention by those skilled in the art.

Claims

1. A lamination mechanism, characterized in that, The lamination mechanism includes a heating plate, a pressure frame, a pressure plate, and several elastic load-bearing components, wherein: The pressure frame is fixedly connected to the periphery of the heating plate; The edge of the pressure plate is levitably suspended on the pressure frame by a plurality of elastic bearing components. The elastic bearing components include a support block, a first spring and a second spring. The support block is fixedly connected to the pressure frame. The first spring and the second spring are disposed on the support block and located below the edge of the pressure plate, and both can extend and retract in the vertical direction. The peripheral edge of the pressure plate is sealed to the pressure frame. A sealed upper chamber is formed between the upper side of the pressure plate and the lower side of the heating plate. An open lower chamber is formed on the lower side of the pressure plate. At least one first vent is opened on the side wall of the upper chamber to connect the upper chamber with the outside. At least one second vent is opened on the upper side of the heating plate. When the upper chamber is not inflated, the edge of the pressure plate is supported by the upper end of the first spring, and there is a gap between the edge of the pressure plate and the upper end of the second spring; during the inflation of the upper chamber, the pressure plate is pressed down, and the edge of the pressure plate is supported by the upper ends of the first spring and the second spring.

2. The lamination mechanism as described in claim 1, characterized in that, The spring constant of the first spring is less than that of the second spring.

3. The lamination mechanism as described in claim 1, characterized in that, The elastic bearing component includes a first guide rod and a second guide rod, one end of the first guide rod being fixed to the support block or the pressure plate, and one end of the second guide rod being fixed to the support block or the pressure plate; The first spring is sleeved on the outside of the first guide rod; The second spring is sleeved on the outside of the second guide rod.

4. The lamination mechanism as described in claim 1, characterized in that, The lamination mechanism further includes a plurality of elastic support components, which are installed in the pressure plate and are disposed away from the pressing area of ​​the pressure plate. The elastic support components have a support surface that extends downward from the lower side of the pressure plate.

5. The lamination mechanism as described in claim 4, characterized in that, The elastic support assembly includes at least one first elastic support unit and at least one second elastic support unit, wherein: The pressure plate has mounting holes corresponding to the first elastic support unit and the second elastic support unit. Both the first elastic support unit and the second elastic support unit include a bushing, a support portion, and a third spring, wherein: The bushing is installed in the corresponding mounting hole, and the upper end of the bushing includes a first limiting part, on which a through hole is provided; The support portion passes through the bushing, the upper end of the support portion includes a second limiting portion that is limited to the upper side of the through hole, and the lower end of the support portion includes a support step that extends downward through the bushing; The third spring is sleeved on the support portion, the upper end of the third spring elastically presses against the first limiting portion of the bushing, and the lower end of the third spring elastically presses against the support step. The lower end surface of the support step constitutes the support surface of the elastic support assembly.

6. The lamination mechanism as described in claim 5, characterized in that: The elastic coefficient of the third spring in the first elastic support unit is equal to that of the first spring, and the elastic coefficient of the third spring in the second elastic support unit is equal to that of the second spring.

7. The lamination mechanism as described in claim 5, characterized in that: The support portion includes a first support member and a second support member, wherein: The first support member passes through the bushing, and the upper end of the first support member forms the second limiting part. The first support member is provided with an insertion hole. The second support member is fixedly connected to the first support member via the insertion hole, and the support step is disposed at the lower end of the second support member.

8. The lamination mechanism as described in claim 5, characterized in that, The elastic support assembly also includes a sealing cap, which is sealed and mounted on the upper surface of the pressure plate, and the mounting hole is located inside the sealing cap.

9. The lamination mechanism as described in claim 1, characterized in that, The lamination mechanism further includes a support body, which is arranged on the upper side of the pressure plate and / or the lower side of the heating plate.

10. The lamination mechanism as claimed in claim 1, characterized in that, The lamination mechanism further includes a driving component, a drive shaft, a driven shaft, and a conveyor belt, wherein: The drive shaft is disposed at the first end of the pressure frame and / or the heating plate, the driven shaft is disposed at the second end of the pressure frame and / or the heating plate, and the conveyor belt is wound around the drive shaft and the driven shaft, and covers the heating plate, the pressure frame and the pressure plate; The driving component is disposed on the pressure frame and / or the heating plate and is connected to the drive shaft for transmission. The driving component is used to drive the drive shaft to rotate so as to drive the conveyor belt to transport.

11. A laminator, characterized in that, The laminator includes a top cover, at least two lifting drive mechanisms, and n lamination mechanisms as described in any one of claims 1 to 10, wherein: The top cover and the n lamination mechanisms are arranged in layers from top to bottom; The lifting drive mechanism is configured to drive the top cover and n laminating mechanisms to rise, such that adjacent laminating mechanisms, the top cover, and the uppermost laminating mechanism move away from each other to open the laminator; and to drive the top cover and n laminating mechanisms to fall, such that adjacent laminating mechanisms, the top cover, and the uppermost laminating mechanism move closer to each other to close the laminator. n≥2。

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