Multi-Layer Multi-Cavity Lamination for Continuous Solar Module Throughput
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Solution Overview
Problem
Existing laminators for solar cell modules are mostly multi-layer single-cavity types, leading to reduced production efficiency due to the need for sequential processing, which limits throughput.
Innovation Solution
A multi-layer and multi-cavity laminator design with multiple laminating devices connected by a transitional conveyance device and equipped with lifting conveyance devices for automatic loading and unloading, allowing continuous processing and enhanced production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a multi-layer single-cavity laminator is used, then the device structure is simple, but the production efficiency is reduced due to sequential processing
Solution Approach 1:
The patent divides the single laminating cavity into multiple independent laminating devices (first, second, and third laminating devices) that operate in parallel or sequence. Each laminating device can process solar cell modules independently, allowing multiple layers to be laminated simultaneously or with minimal waiting time, thereby resolving the contradiction between maintaining simple structure and improving production efficiency.
Solution Approach 2:
The patent transitions from a single-cavity (one-dimensional processing flow) to a multi-cavity three-dimensional arrangement with multiple laminating devices stacked or arranged in space. This spatial dimensionality change allows concurrent processing of multiple layers, dramatically improving productivity while the modular design keeps each individual device relatively simple.
2Productivity
If multiple laminating devices are used in sequence, then production efficiency is improved, but the device complexity increases
Solution Approach 1:
The patent combines multiple laminating devices with feeding and conveyance functions into an integrated multi-layer laminating system. The feeding device can simultaneously supply multiple laminating devices, and the conveyance device coordinates transport across all devices, merging their functions to achieve high production volume while managing complexity through systematic integration rather than isolated components.
3Productivity
If sequential lamination processing is used, then the device structure is simple, but the production time is extended
Solution Approach 1:
The patent ensures continuous operation by designing the feeding device to simultaneously supply multiple laminating devices and the conveyance device to maintain uninterrupted material flow between them. This eliminates idle waiting time between lamination steps, achieving continuous useful action that reduces production time while the coordinated configuration manages system complexity.
Data Source
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AI summary
A multi-layer and multi-cavity laminating machine including a multi-layer feeding device, at least two multi-layer laminating devices, and a multi-layer finished product conveying device connected in sequence is provided. The number of multi-layer laminating devices are increased, and the laminating steps are carried out step by step. After completing the first laminating step, the solar cell module can be transported to the next multi-layer laminating device, so that the next solar cell module can be transported to the previous multi-layer laminating device, thereby improving production efficiency. In the same production time, it is possible to increase the production quantity or reduce the production time by producing the same quantity of products.