Profiled Panel Lamination with Flexible Membranes and Uniform Pressure
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Solution Overview
Problem
Existing lamination devices for photovoltaic stacks on profiled metallic panels suffer from non-uniform lamination due to insufficient pressure distribution, and they cannot adapt to different panel profiles without shutting down the device.
Innovation Solution
A lamination device with a chassis and lid configuration that forms airtight chambers, featuring crenellated cross-sections or profiles to match panel profiles, allowing for uniform pressure application and sequential lamination of panels with different profiles without shutdown.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a roll is used to exert pressure during lamination, then the lamination process can be performed, but the pressure is not homogeneous enough to provide uniform lamination
Solution Approach 1:
The patent uses a flexible membrane instead of a rigid roll to apply pressure. The membrane can conform to the profiled metallic panel surface, distributing pressure uniformly across the entire lamination area including corners and edges, thereby achieving homogeneous pressure distribution and uniform lamination quality.
Solution Approach 2:
The patent employs pneumatic pressure through a sealed chamber to apply uniform distributed pressure across the flexible membrane. This pneumatic system ensures even pressure distribution over the entire contact area, eliminating the pressure non-uniformity issues associated with mechanical rolls.
2Manufacturing precision
If the lamination device is adapted to a specific panel profile, then lamination quality improves, but the device cannot laminate panels with different profiles without shutdown and adaptation
Solution Approach 1:
The flexible membrane can adapt to various panel profiles without requiring device reconfiguration. Its flexibility allows it to conform to different surface geometries while maintaining uniform pressure distribution, enabling the device to laminate panels with different profiles sequentially without shutdown or adaptation.
Solution Approach 2:
The lamination device is designed with universal capability to handle multiple panel profiles through the flexible membrane system. The same device configuration can laminate different profile types by simply changing the panel, without requiring mechanical adjustments or adaptations, thus achieving multi-functionality.
3Manufacturing precision
If heating is applied during lamination, then the photovoltaic stack bonds properly, but thermal gradients affect lamination uniformity
Solution Approach 1:
The flexible membrane acts as a thermal interface that distributes heat uniformly across the photovoltaic stack during lamination. By conforming to the panel profile and maintaining intimate contact, it ensures even thermal distribution, reducing thermal gradients while achieving proper bonding.
Solution Approach 2:
The flexible membrane serves as an intermediary between the heating system and the photovoltaic stack. It mediates heat transfer by distributing thermal energy uniformly across the stack surface, preventing localized overheating and reducing thermal gradients that would compromise lamination uniformity.
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
Ensures uniform lamination of photovoltaic stacks on profiled metallic panels, reduces thermal gradients, and allows seamless switching between panel profiles without device adjustments, enhancing lamination quality and efficiency.
Implementation Method 1
an airtight chamber that can be ventilated or evacuated
Implementation Method 2
a lower heating device whose upper side has a crenellated cross-section
Data Source
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AI summary
The invention relates to a set comprising a profiled metallic panel, and a lamination device for laminating a photovoltaic stack on a profiled metallic panel, the lamination device comprising a lid covered on its underside with an upper flexible pressure membrane so as to form an airtight upper chamber that may be ventilated or evacuated and/or comprising an upper heating device whose bottom side has a crenellated profile, the device also comprising a chassis covered on its top with a lower flexible pressure membrane so as to form an airtight lower chamber that may be ventilated or evacuated and/or comprising a lower heating device whose upper side has a cross-section which differs from the crenellated profile of the bottom side of the upper heating device, wherein the lid is capable of sealably laying on the chassis so that the cavity thus formed is airtight and may be ventilated or evacuated.