Solar Laminating Carrier with Air Cushion Transport
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for transporting and processing solar cell laminates in lamination plants are prone to breakage due to friction and shocks, especially when using rollers and conveyer belts, which are not suitable for large, brittle solar laminates with uneven conveying surfaces.
Innovation Solution
A carrier assembly with a heat conductive housing and an air supply system that creates an air cushion for friction-free movement, combined with a thermal transfer system for heating and cooling, allowing for the safe and efficient handling and processing of solar cell laminates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rollers and conveyer belts are used for transporting solar cell laminates, then the transport mechanism is simple and cost-effective, but the friction and shocks cause breakage of brittle solar laminates
Solution Approach 1:
The patent employs an air cushion system where compressed air is supplied through channels in the carrier assembly to create a layer of air between the solar laminate and the conveying surface. This pneumatic mechanism eliminates direct contact and friction, preventing breakage of brittle solar laminates during transport while maintaining a relatively simple overall system structure.
Solution Approach 2:
The invention replaces the traditional mechanical contact-based transport system (rollers and conveyer belts) with a non-contact air cushion system. This substitution eliminates the harmful mechanical friction and shocks that cause breakage, while the carrier assembly integrates the air supply channels to achieve this without excessive complexity.
2Manufacturing precision
If heating is applied to cure the encapsulating layer, then the solar laminate is properly processed, but the heating time and energy consumption increase
Solution Approach 1:
The patent introduces a heat conductive housing as an intermediary between the heating source and the solar laminate. This housing acts as a thermal mediator that efficiently transfers heat to the encapsulating layer, enabling proper curing while reducing the overall heating time and energy consumption compared to direct heating methods.
Solution Approach 2:
The invention utilizes phase change of the encapsulating layer (from liquid to solid during curing) as a parameter change mechanism. By controlling the heating process to facilitate this phase transition, the system achieves proper curing quality while optimizing the heating time and energy requirements.
3Productivity
If rapid cooling is applied after curing, then the processing efficiency increases, but thermal stress may cause deformation or breakage
Solution Approach 1:
The heat conductive housing serves as a thermal intermediary that facilitates controlled heat transfer during cooling. This intermediary enables rapid cooling to improve processing efficiency while distributing thermal stress evenly, preventing deformation or breakage of the cured solar laminate.
Solution Approach 2:
The patent implements a controlled cooling process where the housing gradually reduces temperature from the curing state. This beforehand cushioning approach prevents sudden thermal shock that could cause deformation or breakage, while still achieving rapid enough cooling to maintain high processing efficiency.
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 a friction-free and shock-free transport mechanism, reducing the risk of breakage and enabling efficient heating and curing of solar cell laminates, while also allowing for rapid cooling and improved handling of large and undulated solar laminates.
Implementation Method 1
an air supply system for providing a continuous outward airflow through said first plurality of apertures when said lower plate is received on a conveying surface of said lamination plant, said airflow yields an elevated and substantially balanced air pressure on said lower plate for providing lift or buoyancy to said carrier housing allowing a substantially friction-free movement of said carrier housing in relation to said conveying surface
Implementation Method 2
a thermal transfer system providing thermal energy to said upper plate for allowing said encapsulating layer to melt and subsequently cure
Implementation Method 3
said encapsulating layer having a specific melting temperature and a specific curing temperature... for allowing said encapsulating layer to melt and subsequently cure
Implementation Method 4
at a temperature of about 130° C. the EVA film cures by polymerization
Data Source
AI summary
A carrier assembly is provided for solar cell laminates that include an encapsulating layer and that are conveyed through a lamination plant having a conveying surface. The assembly includes a housing of heat conductive material defining an inner volume, the housing having an upper plate for receiving the laminates and a lower plate defining a plurality of apertures, the inner volume including at least one connecting element interconnecting the first and second plates. An air supply system provides a continuous outward air flow through the apertures when the lower plate is received on the conveying surface, wherein the airflow yields an elevated pressure on the lower plate for providing lift to the housing, allowing substantially friction-free movement of the housing relative to the conveying surface. A thermal transfer system provides thermal energy to the upper plate for melting and curing the encapsulating layer.