Multi-Chamber Laminating Press for Uniform Heat and Pressure
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Solution Overview
Problem
Existing laminating devices face challenges in efficiently producing different types of photovoltaic modules and glass laminates in a single press, leading to increased cycle time, resource utilization, and quality issues due to uneven heat distribution and membrane-based processes requiring multiple stages.
Innovation Solution
A laminating device with a movable pressure plate and separable pressure chambers allows for flexible operation as a flat press or membrane press, enabling simultaneous heat application from both sides and independent control of pressure, reducing the need for multiple stages and improving long-term stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a membrane-based process is used for laminating, then the workpiece can be pressed with distributed pressure, but the process requires multiple stages and increases cycle time
Solution Approach 1:
The working chamber is divided into multiple separable pressure chambers (first pressure chamber, second pressure chamber, third pressure chamber) that can be independently controlled. This segmentation allows different pressure levels to be applied to different regions of the workpiece simultaneously, achieving the pressure distribution benefit of membrane processes while eliminating the need for multiple sequential stages.
Solution Approach 2:
The pressure chambers are designed to be dynamically adjustable, allowing the operator to set different pressure levels in each chamber based on the specific lamination requirements. The movable pressure plate can also be positioned at different heights to create varying pressure zones, enabling flexible adaptation to different workpiece types and sizes within a single cycle.
2Device complexity
If heat is applied from one side only, then the device structure is simpler, but heat distribution is uneven leading to quality issues
Solution Approach 1:
The heating system is designed with asymmetric heating capabilities where the first pressure chamber can be heated independently from the second and third pressure chambers. This allows the upper and lower sides of the workpiece to receive different heat inputs as needed, enabling uniform heat distribution across the entire workpiece thickness while maintaining structural flexibility.
Solution Approach 2:
Heat application is extended from a single-direction approach to multi-dimensional heating by enabling independent temperature control in different pressure chambers. This allows heat to be applied from multiple sides and at different rates, achieving uniform thermal distribution throughout the workpiece volume rather than just from one direction.
3Adaptability or versatility
If multiple press stages are used to produce different photovoltaic modules, then product variety is increased, but resource utilization decreases and cycle time increases
Solution Approach 1:
The laminating device is designed as a universal press capable of producing multiple types of photovoltaic modules (glass-foil, glass-glass, glass-cell-glass) and other glass laminates within a single working chamber. The separable pressure chambers and adjustable pressure plate allow the same device to be configured for different product types without requiring separate dedicated presses, thereby maximizing resource utilization and reducing cycle time.
Solution Approach 2:
The device allows for dynamic changes in process parameters including pressure levels in different chambers, temperature settings, and pressure plate positioning. By adjusting these parameters rather than changing the entire press configuration, the same physical device can adapt to produce different photovoltaic module types efficiently, improving both versatility and productivity.
4Device complexity
If a fixed pressure plate is used, then the device structure is simpler, but flexibility in operation modes is reduced
Solution Approach 1:
The pressure plate is designed as a movable component that can be positioned at different heights and removed entirely when needed. This dynamic design allows the device to switch between different operation modes (flat press mode, membrane press mode, combined mode) by simply adjusting or removing the pressure plate, providing operational flexibility without significant structural complexity.
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 device enables efficient production of diverse glass laminates and photovoltaic modules in a single unit, reducing cycle time, power consumption, and enhancing product quality by allowing for defined process parameters and flexible operation modes.
Implementation Method 1
The flexible gas-tight element divides the working chamber into a first pressure chamber that is located above the flexible gas-tight element and a second pressure chamber that is located below the flexible gas-tight element and in which the movable pressure plate is arranged, whereby the movement of the movable pressure plate is effected due to a difference of pressure between the pressure chambers
Implementation Method 2
simultaneous heat application from both sides
Implementation Method 3
at least one layer of adhesive such as e.g. PVB which is capable of being activated and/or melted and/or hardened using pressure and/or heat
Data Source
AI summary
The invention relates to a laminating device (10) and a laminating method for laminating at least one layer stack (11), comprising at least one substantially plate-shaped workpiece (11a) and at least one adhesive material layer (11b), by means of pressure and/or heat. The laminating device comprises a lower part (12) and an upper part that can be connected to the lower part (12) in a gas-tight manner. A working chamber (14) which can be opened and closed and which is for receiving the layer stack (11) during lamination is formed between the lower part (12) and the upper part (13). A pressure plate (15) can be moved along a press axis (a-a) in the working chamber (14) between the upper part (13) and the lower part (12). At least one sealing frame (21) is arranged between the lower part (12) and the upper part (13). Multiple pressure chambers that can be separated from one another and actuated as required are arranged in the working chamber (14), wherein multiple clamping points are provided spaced apart from one another in the direction of the press axis (a-a), wherein at least one flexible element is secured on one of the clamping points for separating a first pressure chamber (18), and the moveable pressure plate (15) can be moved via the application or non-application of pressure or negative pressure to said pressure chamber. Given that the flexible gas-tight element divides the working chamber (14) into a first pressure chamber (18) located above the flexible gas-tight element and a second pressure chamber (19) located below the flexible gas-tight element and in which the moveable pressure plate (15) is arranged, wherein the movement of the moveable pressure plate (15) occurs due to a pressure difference between the pressure chambers (18, 19), different operating modes of a laminating device can be performed in one unit.