Laminating Device Force Distribution Element
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Solution Overview
Problem
Existing laminating devices for photovoltaic modules face issues with deformation and delamination in edge areas due to uneven force distribution during the lamination process, leading to bubble formation and reduced quality of the laminate.
Innovation Solution
A laminating device with a force distribution element is introduced between the membrane and the lamination object, allowing for controlled distribution of pressure over a partial area of the membrane-side surface, reducing deformation and delamination risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a membrane press is used for lamination, then the lamination process can be performed with controlled pressure and temperature, but the membrane causes deformation in corner and edge areas leading to delamination and bubble formation
Solution Approach 1:
A force distribution element is introduced as an intermediary component between the membrane and the lamination object. This element has a larger surface area than the membrane contact area, allowing it to distribute the concentrated forces from the membrane over a broader area, thereby preventing edge deformation and delamination while maintaining the temperature and pressure control benefits of the membrane press
2Manufacturing precision
If a laminating body with a core is placed between glass cover and back glass, then edge seal deformation can be reduced, but the device complexity increases
Solution Approach 1:
The force distribution function is extracted from the complex laminating body with core structure and implemented through a simpler, dedicated force distribution element. This element can be a simple plate or pad made of suitable material, eliminating the need for complex multi-component laminating bodies while achieving the same edge seal protection
3Force
If a press plate is applied to cover the upper surface, then the entire surface can be pressurized and heated, but an additional mounting step is required before lamination
Solution Approach 1:
The force distribution element is merged with the existing membrane press structure, combining the pressure distribution function with the heating and lamination functions in a single integrated system. This eliminates the need for separate press plate mounting steps while maintaining uniform pressure and temperature application
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
The solution effectively minimizes deformation and bubble formation in edge areas, enhancing the quality of the laminate by ensuring even force distribution and reducing the need for additional mounting steps, thereby simplifying the manufacturing process.
Implementation Method 1
an upper glass plate can deform, particularly in corner and edge areas, due to the elasticity of a membrane of a membrane press
Implementation Method 2
A desired pressure and/or a desired temperature can be provided in a known manner by means of the laminating device
Data Source
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Figure 5
AI summary
The invention relates to a laminating device and to a method for producing at least one laminate, said laminating device (1) comprising at least one membrane element. The laminating device (1) comprises at least one force distributing element (15a, 15b, 15c), wherein a laminating force which can be transmitted onto a lamination object by the membrane element can be distributed onto at least one subregion of a membrane-side surface (10) of the lamination object via the at least one force distributing element (15a, 15b, 15c). The at least one force distributing element (15a, 15b, 15c) is held on the laminating device (1).