Solar Panel Lamination Pre-heating Uniform Heating
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Solution Overview
Problem
Existing solar panel manufacturing processes face inefficiencies due to non-uniform heating and long residence times in laminators, leading to reduced productivity and increased costs, while also being environmentally unfriendly and complex.
Innovation Solution
A method and device where at least one layer of the solar panel is pre-heated and assembled under vacuum or gas atmosphere, allowing for faster and more uniform lamination without the need for extensive heating within the laminator, using a movable working chamber with temperature control and elastic seals to ensure efficient layer integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the glass plate is heated directly by the heating plate in the laminator, then the heating process is faster, but the glass plate warps upward or downward causing non-uniform temperature distribution
Solution Approach 1:
The heating process is segmented into two stages: pre-heating the glass plate separately before lamination, then completing the heating during lamination. This segmentation allows the glass to be heated uniformly in the pre-heating stage without warping, and then rapidly heated to curing temperature during the controlled lamination stage, resolving the contradiction between heating speed and temperature uniformity.
Solution Approach 2:
The glass plate is pre-heated to a lower temperature (e.g., 50-100°C) before being placed in the laminator. This preliminary action removes the glass from the cold state, reducing thermal shock and warping during subsequent heating, while still requiring completion of the heating process during lamination to reach the curing temperature of the encapsulant material.
2Manufacturing precision
If pins are used to support the glass plate to prevent warping, then temperature uniformity is improved, but the heating process becomes slower
Solution Approach 1:
The glass plate is pre-heated before lamination, which reduces the temperature differential during the lamination heating process. This preliminary heating action decreases the total heating time required during lamination while maintaining temperature uniformity, eliminating the need for pins that would slow down the process.
Solution Approach 2:
The pre-heating step skips the problematic cold-start phase where warping occurs, allowing the lamination process to rush through the critical heating phase more quickly. By already being warm, the glass plate can be heated to curing temperature faster without developing warping issues that would require pin support.
3Loss of time
If the glass plate is pre-heated before construction of the sandwich build up, then the residence time in the laminator is reduced, but the EVA foil may melt and form bubbles
Solution Approach 1:
The pre-heating temperature is controlled to be below the melting point of the EVA foil (e.g., 50-100°C), while the final curing temperature during lamination reaches the required level (e.g., 100-150°C). This parameter control allows time reduction without bubble formation by separating the pre-heating and curing temperature stages.
Solution Approach 2:
The glass plate is pre-heated to a controlled low temperature that does not melt the EVA foil, removing moisture and reducing thermal mass before lamination. This preliminary action reduces residence time while avoiding bubble formation by keeping the pre-heating temperature below the EVA melting point, then completing the heating during the controlled lamination process.
4Reliability
If the sandwich build up is heated to melting temperature of EVA foil, then good curing and interconnection is achieved, but the residence time is long reducing productivity
Solution Approach 1:
The glass plate is pre-heated before lamination, reducing the temperature differential that needs to be overcome during the lamination process. This preliminary heating action shortens the residence time required to reach curing temperature while maintaining curing quality, thereby increasing throughput rate.
Solution Approach 2:
The pre-heating step skips the slow initial heating phase, allowing the lamination process to rush through the critical curing phase more quickly. By already being warm, the sandwich build up reaches the EVA curing temperature faster, maintaining curing quality while reducing residence time and increasing productivity.
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 residence time and cycle time in the laminator, enhances productivity, and achieves a more robust, cost-effective, and environmentally friendly solar panel production process by preventing gas entrapment and ensuring uniform heating.
Implementation Method 1
at least one layer is pre-heated and put together under vacuum or gas atmosphere with at least one other layer
Implementation Method 2
put together under vacuum or gas atmosphere
Data Source
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AI summary
The present invention relates to a method for producing a layer constructed of solar panel built up of a plurality of layers, wherein at least one layer is preheated and put together under vacuum or gas atmosphere with at least one other layer.