Plate Pressing Laminator for Solar Module Bubble Prevention
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Solution Overview
Problem
Existing laminators using membranes for pressure application in solar cell module lamination face issues such as membrane damage, corner bubbles, and side warping due to inconsistent pressure, which increases production costs and reduces efficiency.
Innovation Solution
A plate pressing type laminator with sequentially arranged plate-shaped pressing members that form a chamber for the workpiece, using a lift driving device for mechanical pressure application and an elastic sealing member for sealing, allowing for consistent pressure distribution and vacuumization to prevent bubbles and warping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a membrane is used to apply pressure in the lamination chamber, then the chamber can be vacuumized to remove bubbles, but the membrane swells into a cambered surface causing inconsistent pressure distribution
Solution Approach 1:
The patent removes the membrane component from the pressure application system entirely. Instead of using a membrane to seal and pressurize the chamber, the invention uses a rigid pressing plate that directly applies pressure to the workpiece. This extraction of the membrane eliminates the swelling problem and the resulting cambered surface, thereby resolving the contradiction between bubble removal capability and pressure distribution uniformity.
Solution Approach 2:
The patent introduces a rigid pressing plate as an intermediary between the vacuum chamber and the workpiece. This pressing plate serves as a mediator that distributes pressure uniformly across the workpiece surface without deforming, unlike the membrane which swells and creates uneven pressure. The pressing plate maintains contact with the workpiece while preventing the formation of a cambered surface.
2Force
If greater pressure is applied during pressing to accommodate reduced glass thickness and PVB foil bonding, then the membrane bearing capacity requirement increases, but the membrane service life decreases
Solution Approach 1:
The patent replaces the disposable membrane with a durable, reusable pressing plate. The pressing plate is designed to withstand high pressing pressures repeatedly without degrading, unlike the membrane which has limited service life under high pressure. This substitution eliminates the need for frequent membrane replacements and reduces operational costs while maintaining the required pressing force for reduced glass thickness applications.
Solution Approach 2:
The patent changes the physical state and material properties of the pressure application component from a flexible, thin-walled membrane to a rigid, structurally robust pressing plate. This parameter change enables the system to withstand higher pressing pressures indefinitely, transforming the temporary, pressure-limited membrane into a permanent, pressure-resistant component that can accommodate varying production requirements including reduced glass thickness and PVB foil bonding.
3Ease of manufacture
If a membrane is used for pressure application, then the lamination process can be performed, but the corners are prone to generate bubbles and sides to open and warp
Solution Approach 1:
The patent removes the membrane component that causes corner bubbles and side warping. By replacing the membrane with a rigid pressing plate, the system eliminates the source of geometric inaccuracies while retaining the essential lamination function. The pressing plate provides stable, uniform pressure without deforming into a cambered surface, thereby preventing corner bubble formation and side warping.
Solution Approach 2:
The patent employs a rigid pressing plate that pre-establishes uniform pressure distribution across the entire workpiece surface before lamination begins. This prior cushioning of pressure prevents localized stress concentrations at corners and edges that would otherwise cause bubbles and warping. The rigid structure of the pressing plate ensures consistent pressure application throughout the lamination process, protecting against geometric defects.
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 provides consistent pressure application, reduces membrane consumption, and enhances production efficiency by using mechanical external force for pressure, improving the bearing capacity and reducing the need for frequent membrane replacements, thus lowering operational costs.
Implementation Method 1
the lower chamber is vacuumized to remove bubbles from each layer of the module before lamination
Implementation Method 2
an elastic sealing member is arranged between adjacent plate-shaped pressing members, wherein the elastic sealing member completely or intermittently seals the chamber
Data Source
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AI summary
The present invention provides a novel plate pressing type laminator and a pressure applying method, which are aimed at solving the problems that membranes are prone to damage, edges and corners of laminated modules are prone to generate bubbles, and edges of the module are prone to open up when laminators and laminating methods in the prior art are used for lamination. The laminator includes a lift driving device and a plurality of plate-shaped pressing members which are sequentially arranged from top to bottom, wherein a chamber for accommodating a workpiece is formed in a space between two adjacent plate-shaped pressing members when they are pressed against each other, the chamber forming an pressing layer; and the lift driving device drives the plurality of plate-shaped pressing members to press against one another or move away from one another and provides an pressure for mutual pressing, and the workpiece is pressed through the pressure between the plate-shaped pressing members. By using the plate pressing type laminator and the pressure applying method provided by the present invention, membranes are not prone to damage, edges and corners of laminated modules are not prone to generate bubbles, and edges of the modules are not prone to open up, the laminated modules have strong pressure bearing capacity, a pressure applying speed is increased, the consumption of membranes is avoided, and higher cost-effectiveness is achieved.