Corner Laminating Jig Structure for Solar Cell Modules

Solution Overview

Problem

Existing laminating processes for solar cell modules risk damaging corners due to excessive pressure from diaphragm sheets and require cumbersome frame mounting and removal, reducing productivity.

Innovation Solution

A jig comprising a first and second body with protrusions and holes, designed to contact only the corners of the solar cell module, which redirects pressure away from the corners and facilitates easy installation and removal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If a quadrangular frame is used to surround the solar cell module, then corner damage is prevented, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improvecorner damageVSAvoidframe structure

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The frame structure is divided into multiple L-shaped jigs, each protecting one corner of the solar cell module. This segmentation reduces the complexity of manufacturing and managing a single large frame while maintaining corner protection functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The corner protection function is extracted from the overall frame structure. Instead of using a complete quadrangular frame, only the necessary corner portions are retained as separate L-shaped jigs, eliminating unnecessary structural complexity.

Inventive Principle:

Principle #2Taking out (Extraction)

2Object-affected harmful factors

If a quadrangular frame is used to surround the solar cell module, then corner damage is prevented, but productivity is reduced due to cumbersome mounting and removal tasks

Engineering Contradiction:

Improvecorner damageVSAvoidlaminating process efficiency

Core Design Contradiction:

Object-affected harmful factorsVSProductivity

Solution Approach 1:

The frame structure is divided into multiple L-shaped jigs, each protecting one corner of the solar cell module. This segmentation reduces the complexity of manufacturing and managing a single large frame while maintaining corner protection functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The corner protection function is extracted from the overall frame structure. Instead of using a complete quadrangular frame, only the necessary corner portions are retained as separate L-shaped jigs, eliminating unnecessary structural complexity.

Inventive Principle:

Principle #2Taking out (Extraction)

3Object-affected harmful factors

If a quadrangular frame is used to surround the solar cell module, then corner damage is prevented, but the number of workers required increases

Engineering Contradiction:

Improvecorner damageVSAvoidmounting operation

Core Design Contradiction:

Object-affected harmful factorsVSEase of operation

Solution Approach 1:

The frame structure is divided into multiple L-shaped jigs, each protecting one corner of the solar cell module. This segmentation reduces the complexity of manufacturing and managing a single large frame while maintaining corner protection functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The corner protection function is extracted from the overall frame structure. Instead of using a complete quadrangular frame, only the necessary corner portions are retained as separate L-shaped jigs, eliminating unnecessary structural complexity.

Inventive Principle:

Principle #2Taking out (Extraction)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Protects corners from damage, reduces the need for multiple workers, and simplifies the laminating process by minimizing contact area and ease of jig removal.

Implementation Method 1

there is concern that a problem may occur in which, due to an excessive pressure applied to corner portions of the solar cell module by the diaphragm sheet, the corner portions may be damaged

Methodology Applied

Scientific EffectPressure redistribution: Pressure Increase

Implementation Method 2

a process in which elements constituting the solar cell module are sequentially overlapped and then compressed using high-temperature heat and vacuum by a laminating device to fix the elements through an encapsulation material

Methodology Applied

Scientific EffectThermal bonding: Heating

Implementation Method 3

compressed using high-temperature heat and vacuum by a laminating device

Methodology Applied

Scientific EffectVacuum compression: Vacuum

Data Source

PatentUS12495637B2Jig for laminating solar cell module

Publication Date: 2025.12.09 HANWHA SOLUTIONS CORP

AI summary

The present disclosure may provide a jig for laminating a solar cell module, the jig including: a first body including a first upper surface and a first side surface adjacent to the first upper surface and having at least a partial area configured to come in contact with one side surface forming a corner of the solar cell module; a second body including a second upper surface and a second side surface adjacent to the second upper surface and having at least a partial area configured to come in contact with another side surface forming the corner; and a fixer disposed in a first groove of the first upper surface and a second groove of the second upper surface and disposed across the first body and the second body to fix the solar cell module, wherein the first upper surface and the second upper surface are positioned to be coplanar, and a thickness of the fixer is less than a thickness of the first groove and a thickness of the second groove.