Membraneless PV Lamination for Irregular Panels With Protruding Edges
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Solution Overview
Problem
Existing laminator systems are incapable of efficiently producing irregular multilayer photovoltaic panels with protruding portions, leading to high production costs, time consumption, and a high probability of assembly errors.
Innovation Solution
A membraneless laminator group and plant that includes a lamination chamber with a movable cover element, a movable rigid plane, and a mould template to adapt to the irregular shape of photovoltaic panels, allowing for automated production of panels with both flat and protruding portions, and a feeding and discharging system to handle protruding edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional laminator systems are used for flat photovoltaic panels, then the lamination process is simple and efficient, but the system cannot produce irregular multilayer panels with protruding portions
Solution Approach 1:
The patent introduces a movable rigid plane that can be dynamically positioned and shaped to match the irregular contours of photovoltaic panels with protruding portions. This movable plane works in conjunction with a mould template that defines the desired irregular shape, allowing the lamination system to adapt to different panel configurations without requiring multiple specialized machines.
Solution Approach 2:
The lamination system is divided into distinct functional components: a feeding unit for loading panels, a lamination chamber with movable cover element and movable rigid plane, and a discharging unit for removing finished panels. This segmentation allows each component to be optimized independently while maintaining overall system versatility for producing irregular multilayer panels.
2Productivity
If manual assembly methods are used for irregular photovoltaic panels, then production time and costs are high, but automated systems cannot handle protruding portions
Solution Approach 1:
The patent employs a floppy adaptive element that can conform to the irregular shape of panels with protruding portions. This flexible element works in conjunction with the movable rigid plane to securely hold and transport panels through the lamination process, enabling automated handling of complex geometries that would otherwise require manual assembly.
Solution Approach 2:
The mould template acts as an intermediary between the movable rigid plane and the irregular photovoltaic panel. It defines the precise shape and positioning required for panels with protruding portions, translating the complex geometry into a form that the automated lamination system can efficiently process.
3Manufacturing precision
If irregular multilayer panels are produced manually, then assembly errors increase, but automated lamination systems lack the precision for complex shapes
Solution Approach 1:
The mould template is designed and positioned in advance to define the exact geometry of the irregular panel with protruding portions. This preliminary preparation ensures that when the panel is loaded into the lamination chamber, the movable rigid plane and floppy adaptive element are already configured to match the required shape, enabling precise automated alignment and assembly without manual intervention.
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 system significantly reduces production time and costs while eliminating manual assembly steps and minimizing defects in irregular multilayer photovoltaic panels.
Implementation Method 1
During the evacuation air phase, the air trapped between the layers is removed by creating a vacuum (approximately 1 mbar) in a designated lamination chamber
Implementation Method 2
heating and melting EVA or any other encapsulant layer
Implementation Method 3
sealing the edges by application of pressure forces, also called compression
Implementation Method 4
maintaining a high temperature at a set point for a certain length of time while applying compression of the layers in order to obtain the polymerization
Data Source
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AI summary
A membraneless laminator group (1) for making irregular multilayer photovoltaic panels (P) of the type having at least one flat portion (P1) and at least one protruding portion (P2) developing transversally with respect to the flat portion (P1), such as a protruding frame or one or more protruding edges, comprises at least one lamination chamber (2) configured to operate in vacuum which includes: an abutment base (3) provided with a supporting plane (3a) for supporting at least one panel (P); a movable cover element (4) movable with respect to the base (3) between an open position, wherein at least one panel (P) can be inserted into the chamber (2) or removed from the latter, and a closed position, wherein the movable cover element (4) engages the base (3) by defining a sealable space (5), closed and isolated from the outside; a movable rigid plane (6) located inside the chamber (2) and movable between a raised position, wherein the movable rigid plane (6) is spaced from the supporting plane (3a) of the base (3) and a lowered position, wherein the movable rigid plane (6) is close to the supporting plane (3a) of the abutment base (3); in an operating condition with an irregular multilayer photovoltaic panel (P) resting on the supporting plane (3a) of the base (3) and the movable rigid plane (6) positioned in the lowered position, the panel (P) is interposed between the movable rigid plane (6) and the supporting plane (3a) of the abutment base (3) and pressed between the movable rigid plane (6) and the supporting pane (3a) of the base (3); one mould template (7) engageable or engaged to the movable rigid plane (6) so that to be located between the movable rigid plane (6) and the supporting plane (3a) of the base (3) on which the panel (P) to be manufactured is leaning on wherein the mould template (7) has a shape configured to adapt the movable rigid plane (6) to the panel (P) and is configured to transmit a pressure force from the movable rigid plane (6) to the flat portion (P1) of the panel (P) to be manufactured when the movable rigid plane (6) is positioned in the lowered position.