PV Module Lamination Cycle Time Reduction
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Solution Overview
Problem
The lamination process for photovoltaic (PV) modules, particularly those using ethylene vinyl acetate (EVA) based encapsulant layers, faces challenges in reducing cycle time due to the need for crosslinking reactions and volatile removal, which increases production costs and complexity.
Innovation Solution
A lamination process involving a polymer composition with silane groups that allows for lamination at lower temperatures and shorter cycle times without the need for crosslinking agents like peroxide or silane condensation catalysts, enabling direct pressure application when the polymer reaches a temperature 3-10°C above its melting point.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If crosslinking reactions and volatile removal steps are added to the lamination process to ensure proper bonding and quality, then the reliability and quality of PV modules are improved, but the lamination cycle time increases and production efficiency deteriorates
Solution Approach 1:
The patent removes the crosslinking agent (peroxide or silane condensation catalyst) from the polymer composition, thereby eliminating the need for crosslinking reactions and volatile removal steps. This extraction of the problematic component allows direct lamination without extended cycle times, resolving the contradiction between quality assurance and production efficiency.
Solution Approach 2:
The patent changes the key parameter of the polymer composition by selecting a polymer without crosslinking functionality. This parameter change fundamentally alters the lamination process, allowing it to proceed without the time-consuming crosslinking and volatile removal steps while still achieving reliable bonding through proper selection of polymer and lamination conditions.
2Strength
If crosslinking agents like peroxide or silane condensation catalysts are introduced to achieve proper lamination bonding, then the strength and adhesion of the laminate are improved, but the process complexity and manufacturing cost increase
Solution Approach 1:
The patent extracts and removes the crosslinking agents (peroxide or silane condensation catalysts) from the system, eliminating the associated complexity of introducing, handling, and controlling these chemicals. The adhesion is achieved through alternative means by selecting appropriate polymer materials and optimizing lamination parameters without requiring additional chemical agents.
Solution Approach 2:
The patent employs a simple polymer composition that does not require expensive crosslinking agents or complex catalytic systems. The polymer itself provides the necessary bonding properties through its inherent characteristics, eliminating the need for additional costly chemical additives and simplifying the overall manufacturing process.
3Productivity
If pressure is applied immediately when the polymer melts to reduce cycle time, then the productivity is improved, but the risk of damaging fragile photovoltaic cells increases due to high stress on insufficiently molten polymer
Solution Approach 1:
The patent changes the melting temperature parameter of the polymer to be lower (below 100°C). This parameter change allows the polymer to melt quickly and reach sufficient fluidity at lower temperatures, enabling pressure to be applied sooner in the heating cycle without risking cell damage from applying pressure to insufficiently molten material, thus reducing cycle time while maintaining cell integrity.
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
This approach significantly reduces lamination cycle time, avoids premature crosslinking issues, and eliminates the need for volatile removal steps, resulting in a more efficient and cost-effective production of high-quality PV modules.
Implementation Method 1
the pressing step (iii) is started when the at least one polymeric layer element reaches a temperature which is at least 3 to 10°C higher than the melting temperature of the polymer (a)
Implementation Method 2
heating step to heat up the multilayer assembly optionally in a chamber at evacuating conditions
Data Source
Figure 1
AI summary
The present invention relates to a lamination process for producing a multilayer laminate which comprises a one or more substrate element(s) and one or more polymeric layer element(s), preferably to a lamination process for producing a photovoltaic (PV) module,and to a PV module laminate.