Vacuum Laminating Press Segmentation for PV Module Curing
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Solution Overview
Problem
Multi-level vacuum laminating presses for photovoltaic modules face challenges in energy efficiency, temperature control, and adhesive residue removal, leading to increased costs and limited cycle time reductions due to complex heating and cooling requirements and the need for manual handling of release films.
Innovation Solution
A method and device that incorporate a multi-level vacuum laminating press followed by a multi-level laminator and cooling device, allowing pre-lamination under vacuum, curing at elevated temperatures without vacuum, and independent temperature control across stations, eliminating the need for release films by operating at lower temperatures where adhesives soften but do not liquefy, and using conveyor belts as flexible pressing means.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a multi-level vacuum laminating press is used to laminate photovoltaic modules, then the processing capacity per unit area is increased, but the energy requirement for heating and cooling cycles increases due to reduced interaction of heating plates with the environment
Solution Approach 1:
The patent divides the laminating process into two separate stages performed in different devices: (1) pre-lamination in a vacuum laminating press at lower temperatures, and (2) curing in a curing oven at elevated temperatures. This segmentation allows each device to be optimized for its specific function, with the curing oven having improved heat retention properties for energy efficiency while the vacuum press handles the bubble removal task.
2Reliability
If the target temperature in the vacuum laminating press is raised above the curing temperature to complete curing under vacuum, then the adhesive layers are fully cured, but adhesive residues contaminate the flexible pressing means and heating plates
Solution Approach 1:
The process is segmented into pre-lamination at lower temperatures in the vacuum press (where adhesive softens but does not liquefy) and curing at elevated temperatures in a separate curing oven. This prevents adhesive residue contamination of the flexible pressing means while ensuring complete curing of the adhesive layers.
Solution Approach 2:
The patent changes the temperature parameter between two stages: lower temperature during vacuum pre-lamination to avoid adhesive liquefaction, and elevated temperature during subsequent curing in the oven to achieve full adhesive cure. This parameter change resolves the contradiction between curing reliability and contamination prevention.
3Object-generated harmful factors
If release films are used to prevent adhesive residue contamination, then the heating plates are protected, but manual handling is required increasing processing time and costs
Solution Approach 1:
By changing the temperature parameter to operate below the liquefaction point of the adhesive during vacuum pre-lamination, the need for release films is eliminated entirely. The adhesive softens enough for bonding but does not liquefy to cause contamination, thus removing the time-consuming manual release film handling steps.
4Reliability
If the flexible pressing means is designed as an elastic membrane stretched over a sealing frame, then vacuum can be applied effectively, but adhesive residues contaminate the membrane and require cleaning or replacement
Solution Approach 1:
The process separates vacuum application (pre-lamination at lower temperature) from curing (elevated temperature in oven). The flexible pressing means is only exposed to the lower temperature stage where adhesive does not liquefy, preventing contamination while maintaining effective vacuum application for bubble removal.
Solution Approach 2:
The temperature parameter is controlled to remain below the adhesive liquefaction point during the vacuum pressing stage, changing the adhesive state from potential contaminant to controlled bonding agent. This parameter control protects the membrane from contamination while maintaining vacuum effectiveness.
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 configuration enhances energy efficiency, reduces adhesive residue issues, and allows for more precise temperature control, enabling faster processing and reduced energy consumption while maintaining adhesive integrity, thus improving the overall laminating process efficiency and cost-effectiveness.
Implementation Method 1
A vacuum chamber is provided in each press floor, which is divided into a product half and a pressure half by a flexible pressing means. The product half of the vacuum chamber is intended to hold at least one workpiece and can be evacuated
Implementation Method 2
When the workpiece comes into contact with the heating plate, the former gradually heats up to above the softening temperature and hardening temperature of the adhesive layers
Implementation Method 3
The workpieces to be laminated have a multi-layer structure and contain at least one adhesive layer with an adhesive, which is activated and hardened by the action of heat
Data Source
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AI summary
The invention relates to a method and a device for laminating substantially plate-shaped workpieces 20, 21 with at least one heat-activated and curable adhesive layer 402 under pressure and heat.A number of workpieces 20, 21 are placed in a multi-stage vacuum laminating press 200, in which the workpieces 20, 21 are laminated under heat in press stages, each with a vacuum chamber divided into a product half 141 and a pressure half 131 by a flexible pressure means 30b, 31b, 32b, 150, 151, wherein the product half 141 of the vacuum chamber, in which at least one workpiece 20, 21 is arranged, is evacuated and the pressure means presses the workpiece 20, 21 directly or indirectly against a bottom side of the vacuum chamber by means of the resulting negative pressure and/or by additionally pressurizing the pressure half of the vacuum chamber, which is arranged on the side of the pressure means facing away from the workpiece 20, 21.The invention is characterized in that the lamination process is interrupted by opening the multi-level vacuum lamination press 200 and the number of pre-laminated workpieces 20, 21 are transferred to a multi-level laminator 201, and that the workpieces 20, 21 in the multi-level laminator 201 are subjected to a temperature at or above the curing temperature of the adhesive layers.