SPACER DEVICE FOR A SYSTEM FOR LAMINATING

Abstract

A spacing device for a system for laminating a laminate, in particular photovoltaic modules. The system includes a membrane holder adapted to apply a membrane to the laminate under pressure for lamination. The spacing device includes a circulating belt and a plurality of spacing members connected to the band and configured to at least partially form a frame for the laminate in at least a portion of the circulating belt and thereby suppress edge compression of the laminate during lamination.

Claims

1. A spacing device for a system for laminating a laminate of photovoltaic modules, the system comprising a membrane holder adapted to apply a membrane to the laminate under pressure for laminating, the spacing device comprising: a circulating belt; and a plurality of spacing members connected to the belt and configured to at least partially form a frame for the laminate in at least a portion of the circulating belt and thereby suppress edge compression of the laminate during lamination.

2. The spacing device according to claim 1, wherein said laminating comprises forming a negative pressure, and wherein: the spacing members are formed such that the formed frame has openings to promote escape of gas from an area in or around the laminate during lamination.

3. The spacing device according to claim 1, wherein fusion of plastic in the laminate occurs during lamination, and wherein the spacing members are formed such that the formed frame has recesses or forms a gap to the laminate to receive exiting plastic during lamination.

4. The spacing device according to claim 1, wherein the membrane holder is formed to apply the membrane to the laminate in a vertical movement, and wherein the spacing members are formed such that when the membrane is applied to the laminate, the formed frame is flush with the laminate.

5. The spacing device according to claim 1, wherein the spacing members comprise at least one of the following materials: steel, plastic, silicone, hard rubber, and a base material with a non-stick coating.

6. The spacing device according to claim 1, wherein the spacing members are interchangeably connected to the circulating belt to form frames having a size and/or height adapted to different laminates.

7. The spacing device according to claim 1, wherein the circulating belt is any one of the following: a conveyor belt adapted to have the laminate placed thereon and transported at least partially through the system for lamination, a release tape configured to interpose between the membrane and the laminate during lamination and to promote release of the membrane from the laminate after lamination.

8. The spacing device of claim 1, wherein the circulating belt is a release band configured to interpose between the membrane and the laminate during lamination and to promote release of the membrane from the laminate after lamination; and wherein the spacing device further comprises: a further circulating belt having further spacing members, the further circulating belt being a conveyor belt adapted to transport the laminate for lamination, and the further spacing members are formed to engage at least some of the spacing members during lamination to form a stepless frame for the laminate and thereby suppress edge compression of the laminate during lamination.

9. The spacing device according to claim 1, wherein the plurality of spacing members comprises at least two spacing members configured to interlock in a zipper-like manner when forming the at least partial frame during lamination.

10. The spacing device according to claim 1, wherein at least one of the spacing members comprises a bevel to extend a service life of the membrane and/or is adapted to build up a pressure towards the laminate when the membrane is applied to the laminate by the mechanical pressure exerted on the spacing member via the membrane.

11. A method of manufacturing a spacing device for a system for laminating a laminate, in particular a photovoltaic module, the system comprising a membrane holder adapted to apply a membrane for lamination to the laminate under a mechanical pressure, the method comprising the steps of: providing a circulating belt; and attaching a plurality of spacing members to the circulating belt such that the spacing members at least partially form a frame around the laminate during lamination, thereby suppressing edge compression of the laminate during application of the membrane to the laminate.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0035] The embodiments of the present invention will be better understood from the following detailed description and accompanying drawings, which, however, should not be construed as limiting the disclosure to the specific embodiments, but are merely for explanation and understanding.

[0036] FIG. 1 shows a spacing device for a system for laminating a laminate.

[0037] FIG. 2 shows twice a cross-section of another embodiment of a spacing device for a system for laminating a laminate.

[0038] FIG. 3 shows views of two embodiments of the spacing device for a conveyor belt guided on drag bars.

[0039] FIG. 4 shows a cross-section for a spacing device attached to tow bars.

[0040] FIG. 5 shows further details of spacing members in a cross-section of a system for laminating with spacing device.

[0041] FIG. 6 shows an illustration of how edge pressing occurs in a conventional system for laminating without a spacing device.

[0042] FIG. 7 shows steps of a method of making a spacing device for a system for laminating a laminate with a membrane.

DETAILED DESCRIPTION

[0043] FIG. 1 shows an embodiment of a spacing device 100 for a system for laminating a laminate 30, in particular photovoltaic modules. The system includes a membrane holder (holding device) 200 configured to apply a membrane 210 to the laminate 30 while exerting pressure for lamination. The spacing device 100 includes a circulating belt 110 guided by pulleys, and a plurality of spacing members 120 connected to the belt and configured to form a frame 150 for the laminate 30 in at least a portion of the circulating belt 110 and thereby suppress edge compression of the laminate 30 by the membrane 210 during lamination .

[0044] In order to avoid edge compression by the membrane 210, the active pressing area of the membrane 210 should not be larger than the laminate 30 to be manufactured. This is achieved here by the plurality of spacing members 120 forming frames 150 for the laminate 30. Advantageously, the frame 150 is only slightly larger than the outer edges of the laminate and is at least the height of the laminate 30 to be manufactured. Advantageously, the laminate 30 is placed in the lamination frame 150 before the process starts. By protecting the frame 150 from over-pressing of the edges by the membrane 210, laminates 30 can be manufactured without edge pressing. A distance of the spacing members 120 from the laminate 30 is also dependent on a placement accuracy of the laminate 30 on the belt 110. The placement accuracy varies between different systems for laminating. In examples, the spacing between the laminate 30 and the frame 150 may be on the order of 3 to 7 mm. Thus, the embodiment example allows for an automated process without manual handling and laminates 30 without edge or edge pressing.

[0045] In the figure shown, the circulating belt 110 in particular transports the laminate 30 through at least parts of the system for lamination. The laminates 30 are conveyed in on such a transport sheet and deposited prior to the start of the process. Embodiments in which a belt 110 other than the transport sheet is formed with spacing members 120 are conceivable. In particular, a plurality of belts 110 may exist whose respective spacing members 120 together form a frame 150 for the laminate 30 during lamination. For this purpose, the spacing members 120 may also interlock in the manner of a zipper.

[0046] In the illustrated figure, the spacing members 120 are fixed to the belt 110. The spacing members 120 may also be larger frame 150 forming structures that need only be connected to the belt 110 at specific locations. The spacing members 120 may be interchangeable, so that different spacing members 120 may be used to form frames 150 for different laminates 30.

[0047] FIG. 2 shows, arranged one above the other, two cross-sections of a part of a system for lamination with a membrane holder 200 and a membrane 210 which is applied to a laminate 30 for lamination. The laminate 30 lies on a circumferential conveyor belt or transport sheet 113 over a hot plate 300. A release belt 115, also circumferential, extends between the membrane 210 and the laminate 30 to protect the laminate 30 from contamination, for example, and to facilitate lifting of the membrane 210 from the laminate 30 after lamination. In systems for laminating, a thickness of the release sheet 300 may be, for example, 0.3 mm. Spacer members 120 are shown adjacent to the laminate 30 to prevent the membrane 210 from pressing over the edges of the laminate 30. In the illustrated embodiment, the spacing members 120 are attached to the sheets 113, 115 in the laminator. Here, attachment to the transport sheet 113 located below the laminate 30 and/or to the release sheet 115 located above the laminate 30 is possible. The frame 150 formed by the spacing members 120 may include openings positioned perpendicular to the laminate 30 to facilitate evacuation of an area around the laminates 30. Bevels 122 on edges of the spacing members 120 increase the service life of the membrane 210.

[0048] In the cross-section shown above in the figure, the membrane 210 is lowered onto the laminate 30 or onto the release sheet 115. As a result, the membrane 210 closes a laminate chamber around the laminate 30. In the lower cross-section, a pressure is shown by the arrows above the membrane 210, which presses the membrane 210 onto the release sheet 115 and laminate 30. The pressure can be created or assisted, for example, by an overpressure of a fluid (e.g. air) above the membrane 210, but also by an evacuation of air from the laminate chamber. During lamination, heat is applied to the laminate 30 for lamination via a heating plate 300 shown below the transport sheet 113.

[0049] FIG. 3 shows two views, one above the other, of each embodiment of the spacing device 100. In each of the two parts of the figure, a top view is shown of a portion of a circulating conveyor belt 113 that is pulled through the system for lamination via drag bars 117. In examples of membrane lamination systems, both a conveyor belt 113 and a release belt 115 (not shown here) are attached to and guided by such drag bars 117 through one or more laminate chambers or portions of the system for lamination. The conveyor belt 113 may be continuous or may be interrupted; in particular, a further section of the conveyor belt 113 may be adjacent to each right side of the drag bar 117, or the conveyor belt 113 may be interrupted there. On the conveyor belt 113, whose direction of rotation in each case points, for example, in the direction of the right edge of the image, a plurality of laminates 30 lie in frames 150 formed from spacer members 120.

[0050] In the upper portion of the figure, the spacing members 120 are attached directly to the conveyor belt 113. The frames 150 may also have spacing members 120 that extend in the direction of transport and are made of stretchable or flexible, but pressure-resistant material that allows the frames 150 to circulate.

[0051] In the lower part of the figure, the frames 150 for the individual laminates 30 are designed as a spacing members 120, which is not directly attached to the conveyor belt but, like the conveyor belt 113, is attached to and guided by the drag bar 117.

[0052] FIG. 4 shows a cross-section for the embodiment example in the lower part of FIG. 3. A lower tow bar 117 and an upper tow bar 118 can be seen, for a circulating direction pointing to the right in the picture. A conveyor belt 113 is attached to the lower tow bar 117, and a release belt 115 is attached to the upper tow bar 118. Both tow bars 117, 118 pull the belts 113, 115 through the system for lamination. The belts 113, 115 can be continuous or interrupted; in particular, a further section of the respective belt 113, 115 can be adjacent to the right side of the tow rods 117, 118, or the respective belt 113, 115 can be interrupted there.

[0053] A spacing member 120 is also attached to the lower drag bar 117, which rests on the conveyor belt 113. The spacing member 120 may be, for example, bolted, welded or clamped to the drag bar 117. The spacing member 120 has frames 150 for one or more laminates 30 (not shown here). The spacing member 120 could alternatively be attached to and pulled by the tow bar 118.

[0054] FIG. 5 shows further details of spacing members 120 for an embodiment of the spacing device 100. Shown is a cross-section through a conveyor belt 113, a laminate 30 framed by spacing members 120, and a part of a membrane holder 200. The spacing members 120 are thereby connected to the conveyor belt 113. They have a shape that is intended to allow material to escape from the laminate 30 during lamination. In particular, for example, EVA from the plastic layer 37 (cf. FIG. 6) can escape from the laminate 30 during lamination. In the illustrated embodiment, the shape of the spacing members 120 is the bevels 125. The spacing members 120 reduce leakage of encapsulant material because the laminate edges are not over-pressed. The risk of sticking is thus already reduced or minimized. The spacing members 120 are given a slope towards the laminate edge by the bevels 125, so that outflowing encapsulation material has as little contact surface with the spacing members 120 as possible. Escaping material passes through this shape onto the conveyor belt 113. In this regard, it is advantageous if the spacing members 120, like the conveyor belt 113, have a non-stick coating of material that prevents escaping material from adhering (such as Teflon).

[0055] In addition, the outer spacing members 120 include bevels 122 that serve to protect the membrane 210 (not shown here), which is pressed on from above. Sharp edges may injure the membrane 210, the thickness of which may be in the range of less than one centimeter; the bevels 122 allow the membrane 210 to nestle over a larger area, thereby increasing a service life of the membrane 210.

[0056] FIG. 7 shows steps of a method for manufacturing a spacing device 100 for a system for laminating a laminate 30, in particular a photovoltaic module, the system comprising a membrane holder 200 adapted to apply a membrane 210 for lamination to the laminate 30 under application of a pressure. A first step comprises providing S100 a circulating belt 110, which may be part of an existing system. A further step comprises attaching S200 a plurality of spacer members 120 to the circulating belt 110, in a manner such that the spacer members 120 at least partially form a frame 150 around the laminate 30 during lamination, thereby suppressing edge compression of the laminate 30 during application of the membrane 210 to the laminate 30.

[0057] The features of the invention disclosed in the description, the claims and the figures may be essential to the realization of the invention either individually or in any combination.

TABLE-US-00001 LIST OF REFERENCE SIGNS 30 laminate 100 distance device 110 circulating belt 113 transport belt (transport sheet) 115 release band (release sheet) 117, 118 tow bars 120 spacing member(s) 122 beveling to increase a membrane service life 125 recess to accommodate escaping (exiting) material 150 frame 200 membrane holder (holding device) 210 membrane 300 heating plate