Laminating Apparatus And Method For Producing A Laminate

Abstract

A laminating device and a method for producing a laminate. The laminating device has at least one membrane element. The laminating device has at least one force distributing element, wherein a laminating force which can be transmitted onto a lamination object by the membrane element can be distributed onto at least one sub region of a membrane-side surface of the lamination object via the at least one force distributing element. The at least one force distributing element is held on the laminating device.

Claims

1-10. (canceled)

11. A laminating apparatus, comprising: at least one membrane element; at least one force distributing element configured to distribute a lamination force that is transferred or exerted by said membrane element to a lamination object to at least a portion of a membrane-side surface of the lamination object via said at least one force distributing element; wherein said at least one force distributing element is mounted to the laminating apparatus.

12. The laminating apparatus according to claim 11, which comprises at least one retaining element for holding said at least one force distributing element.

13. The laminating apparatus according to claim 12, which comprises a lamination stretching frame and wherein said retaining element is fastened to said lamination stretching frame.

14. The laminating apparatus according to claim 13, wherein said retaining element is a fabric web.

15. The laminating apparatus according to claim 12, wherein said retaining element is a fabric web.

16. The laminating apparatus according to claim 11, wherein said force distributing element comprises a panel-shaped section.

17. The laminating apparatus according to claim 11, wherein said force distributing element has a panel shape.

18. The laminating apparatus according to claim 11, wherein said force distributing element comprises at least one support segment for supporting on a surface area of the laminating apparatus.

19. The laminating apparatus according to claim 11, wherein said force distributing element comprises a panel-shaped section or has a panel shape and comprises at least one support segment for supporting on a surface area of the laminating apparatus.

20. The laminating apparatus according to claim 11, wherein said force distributing element has a panel shape, and wherein a surface of said panel-shaped force distributing element has or forms a raised area in a portion of the surface.

21. The laminating apparatus according to claim 11, wherein said force distributing element comprises a panel-shaped section or is panel-shaped and wherein a surface of said panel-shaped force distributing element has or forms a raised area in a portion of the surface.

22. The laminating apparatus according to claim 11, wherein said at least one force distributing element is one of a plurality of force distributing elements each mounted to the laminating apparatus.

23. A method for producing a laminate, the method comprising the following steps: providing a laminating apparatus with at least one force distributing element mounted to the laminating apparatus; arranging at least one lamination object in the laminating apparatus, the lamination object having a membrane-side surface; transferring or exerting a lamination force by the membrane element to the membrane-side surface of the lamination object and distributing the lamination force via the at least one force distributing element to at least one portion of the membrane-side surface; and providing a predetermined pressure to the membrane element and/or a predetermined temperature.

24. The method according to claim 23, which comprises also transferring the lamination force with the at least one force distributing element to a surface area of the laminating apparatus.

Description

[0056] The invention is further explained by way of reference to several embodiments. The figures show:

[0057] FIG. 1 a schematic cross-section of a laminating apparatus according to the prior art,

[0058] FIG. 2 a schematic cross-section of a photovoltaic module produced with edge fold pressing,

[0059] FIG. 3 a schematic cross-section of a laminating apparatus according to the present invention,

[0060] FIG. 4 a schematic cross-section of a laminating apparatus according to the present invention in a further embodiment,

[0061] FIG. 5 a top view of a laminating apparatus according to the present invention with a plurality of module composites,

[0062] FIG. 6a a panel-shaped force distributing element in a first embodiment and

[0063] FIG. 6b a panel-shaped force distributing element in a further embodiment.

[0064] FIG. 1 illustrates a schematic cross-section of a laminating apparatus 1 according to the prior art. A module composite 2 is introduced as a lamination object into a lamination chamber 3 of the laminating apparatus 1. The module composite 2 comprises a front glass panel 4 and a back glass panel 5, which may be referred to as substrate glass panel. The front glass panel 4 may be designed, for instance, as single-pane safety glass. Between the glass panels 4, 5 there is an EVA layer 6 arranged, which connects the glass panels 4, 5 in the laminated state. In an edge area of the module composite 2 there is a sealing layer 7, e.g., a butyl layer arranged, which seals the volume enclosed by the glass panels 4, 5 against external influences. Not shown in the figure is an active layer, which is also arranged between the glass panels 4, 5 and forms the individual solar cells.

[0065] The figure further shows a conveyor belt 11, on which the module composite 2 is transported into the area of the lamination chamber 3. The conveyor belt 12 may be designed, for instance, as a web coated with polytetrafluoroethylene. Also shown is a surface area 12 of the laminating apparatus 1, which also forms a surface area of the lamination chamber 3.

[0066] The laminating apparatus 1 comprises a cover band 8, which may be designed, for instance, as a web coated with polytetrafluoroethylene. Moreover, the laminating apparatus 1 comprises a membrane 9. The cover band 8 is arranged in this case between the membrane 9 and a membrane-side surface 10 of the module composite 2 and may be used as mechanical protection of the membrane-side surface. For a lamination, one side of the membrane 9 facing away from the lamination chamber 3 is exposed to a predetermined pressure such that a desired differential pressure arises between the volumes separated from one another by the membrane, for instance a differential pressure of 800 mbar. The pressure is indicated in this case by arrows pointing in a direction of lamination.

[0067] The lamination chamber 3 may be vacuumized here. Furthermore, a predetermined temperature may be provided in the lamination chamber 3. The membrane 9 comprises a predetermined elasticity, wherein the membrane 9 due to elasticity does not adapt precisely to an edge profile of the module composite 2 and thus has an essentially S-shaped profile in the cross-section in an area B, which is adjacent to a lateral edge of the module composite 2. This profile of the membrane exerts on an edge R of the back glass panel 5 a resulting lamination force, which is in particular greater that a lamination force that acts on a point P, which lies in relation to the back glass panel 5 in an inner section of the back glass panel 5.

[0068] This causes a deformation of the back glass panel 5, the edge area of which is bent in the direction of lamination toward the front glass panel 4. In this way, the sealing layer 7 in particular is displaced in the edge area of the module composite 2.

[0069] FIG. 2 shows a schematic cross-section of a photovoltaic module 13 produced with edge fold pressing. Following the lamination shown in FIG. 1, the back glass panel 5 tends to return again to an initial non-deformed state, in particular the edge area of the back glass panel 5 moves away again from the front glass panel 4 contrary to the direction of lamination. This causes in particular in the edge area a substantial deformation and expansion of the sealing layer 7. Since the sealing layer 7 counteracts this deformation, internal stresses arise. In this way, the sealing layer 7 may detach at least in some areas of the glass panels 4, 5, especially the front glass panel 4, resulting in formation of bubbles 14 in the photovoltaic module 13.

[0070] FIG. 3 illustrates a schematic cross-section of a laminating apparatus 1 according to the present invention, In contrast to the embodiment of the laminating apparatus 1 shown in FIG. 1, the laminating apparatus 1 comprises a force distributing element 15 designed as reinforcement plate. The force distributing element 15 is arranged between the membrane 9 and the membrane-side surface 10 of the module composite 2. A support web 16 for holding the force distributing element 15 is also shown. The cover band 8 is also shown. The support web 16 is arranged between the membrane 9 and the force distributing element 15. The cover band 8 is arranged between the force distributing element 15 and the membrane-side surface 10. It is not absolutely necessary, but preferable, however, to provide a cover band 8.

[0071] It is also possible that the support web 16 is arranged between the force distributing element 15 and the cover band 8 or the membrane-side surface 10. The cover band 8 may also be designed as or provide a support web 16. If there is no cover band 8 provided, the force distributing element 15, in particular at least one part of a surface of the force distributing element 15, may rest directly on the membrane-side surface 10.

[0072] The force distributing element 15 extends here from a lateral edge of the module composite 2 towards a center of the module composite 2, wherein only a portion of the membrane-side surface 10 of the module composite 2 is covered, however, by the force distributing element 15. In particular, the force distributing element may have in this case a width that is less than a width of the module composite 2. A width of the force distributing element may be especially in a range of 1/10 to of the width of the lamination object, in other words the module composite 2.

[0073] The figure also shows that the force distributing element 15 is arranged flush with the lateral edge of the module composite 2. This is not mandatory, however. In particular, the force distributing element 15 may also extend outwardly by a predetermined amount beyond the lateral edge of the module composite 2 or may be offset inwards with a predetermined offset from the lateral edge of the module composite 2.

[0074] The laminating force generated by the pressure on the membrane 9, especially by the laminating force generated by the pressure exerted on the part of the membrane 9 arranged in the area B, which acts on the edge R of the back glass panel 5, is distributed by the force distributing element 15 uniformly to the portion of the membrane-side surface 10 of the module composite 2 which is covered by the force distributing element 15. This prevents or decreases the deformation of the back glass panel 5, especially towards the front glass panel 4, whereby the deformation of the sealing layer 7 is also decreased. Consequently, the risk of bubbles forming as shown in FIG. 2 is reduced.

[0075] FIG. 4 presents a schematic cross-section of the laminating apparatus 1 according to the present invention in a further embodiment. In contrast to the embodiment presented in FIG. 3, the force distributing element 15 has an L-shape in the cross-section. Thus, the force distributing element 15 comprises a panel-shaped section 17 and a support segment 18. The support segment 18 is used here for supporting on the surface area 12. Consequently, a part of the lamination force transferred over the membrane 9 may be directed via the support segment 18 to the surface area 12, wherein a further portion is distributed via the panel-shaped section 17 to the portion of the membrane-side surface 10 of the module composite 2. FIG. 4 illustrates that the support segment 18 is supported on the cover band 8, the carrier web 16 and the transport belt 11 resting on the surface area 12. The support segment 18 may be arranged in this case with a predetermined distance from a lateral edge of the module composite 2. In this way a run of the cover band 18 and the carrier web is not obstructed in an advantageous manner.

[0076] FIG. 5 illustrates a schematic top view of a laminating apparatus 1 according to the present invention. Here it is shown that a plurality, in particular nine, of module composites 2 are arranged in matrix form. In the case presented here, the arrangement comprises three rows with three module composites 2 each. The figure also shows that the module composites 2 are arranged with predetermined distances to one another.

[0077] The laminating apparatus 1 comprises a plurality of force distributing elements 15a, 15b, 15c. The force distributing elements 15a, 15b, 15c may vary in this case in their respective construction, e.g. in their dimensions, wherein like reference numerals designate force distributing elements of the same construction.

[0078] Force distributing elements 15a according to a first embodiment are arranged and designed here in such a way that at least a part of a lamination force is distributed to one corner area of a surface precisely of one module composite 2 and another part is directed to a surface area 12.

[0079] Force distributing elements 15b according to a second embodiment are arranged and designed here in such a way that at least a part of a lamination force is distributed to one corner area of a surface of a first module composite 2 and to a corner area of a surface of a module composite 2 adjacent in a row or column. Another part of the lamination force is directed to the surface area 12.

[0080] Force distributing elements 15c according to a third embodiment are arranged and designed here in such a way that at least a part of a lamination force, especially the entire lamination force, is distributed to corner areas of surfaces of four adjacent module composites 2.

[0081] The figure also shows a carrier web 16, which has a mesh-like construction. The force distributing elements 15a, 15b, 15c may have perforations, not shown, whereby the force distributing elements 15a, 15b, 15c may be fastened, e.g. sewn, via suitable fastening means, for instance, a wire or a thread, to the carrier web 16. This allows for an easy, in particular detachable, fastening of the force distributing elements 15a, 15b, 15c to a desired position and with a desired orientation on the carrier web 16.

[0082] The figure also shows that the carrier web 16 is fastened to an immovable part of the laminating apparatus, namely a lamination stretching frame 19. In this way, the force distributing elements 15a, 15b, 15c are fastened to the laminating apparatus 1.

[0083] FIG. 6a illustrates a force distributing element 15b according to the previously described second embodiment. The force distributing element 15b comprises a panel-shaped section 17 and a support segment 18. The support segment 18 extends here along one side, in particular a long side, of the panel-shaped section 17. Here the support segment 18 is arranged on the edge of the panel-shaped section 17.

[0084] FIG. 6b shows in perspective a force distributing element 15a according to the previously described first embodiment. The force distributing element 15a comprises a panel-shaped section 17, a first support segment 18a and another support segment 18b. The first support segment 18a extends here along a first side of the panel-shaped section 17, wherein the other support segment 18b extends along an adjacent side of the panel-shaped section 17.

[0085] The support segments 18, 18a, 18b may be designed, e.g., as support bars. The support segments 18a, 18b may also be arranged at adjacent edges of the panel-shaped section 17.

[0086] The force distributing elements 15c, shown in FIG. 5, according to the third embodiment may have in this case exclusively a panel-shaped section 17 and no support segment 18. It is also conceivable, however, that the force distributing elements 15c comprise support segments, which protrude into the intermediate areas, shown in FIG. 5, between adjacent module composites 2, whereby the corresponding force distributing elements 15c may be additionally supported on the surface area 12 as shown in FIG. 5.

[0087] FIG. 5 shows that in reference to the arrangement of the module composites 2, force distributing elements 15a, 15b arranged at or over the outer edges of the arrangementhave in each case at least one support segment 18, 18a, 18b. The force distributing elements 15c arranged in relation to the arrangement of a plurality of module composites 2 at or over inner edges of the module composites 2 do not necessarily have to exhibit here a support segment 18, 18a, 18b. In this case, force distributing elements 15a, 15b arranged at or over outer edges of the arrangement may have other dimensions than the force distributing elements 15c arranged at or over inner edges of the arrangement. For instance, force distributing elements 15a, 15b arranged at or over outer edges of the arrangement may exhibit dimensions of 0.2 m0.3 m, while force distributing elements 15c arranged at or over inner edges of the arrangement may exhibit dimensions of 0.3 m0.3 m. However, force distributing elements 15a arranged at or over outer corners of the arrangement may have even other dimensions than the force distributing elements 15b arranged at or over the remaining outer edge sections, for instance, the same dimensions as the force distributing elements 15c arranged at or over the inner edges of the arrangement.

LIST OF REFERENCE NUMERALS

[0088] 1 Laminating apparatus

[0089] 2 Module composite

[0090] 3 Lamination chamber

[0091] 4 Front glass panel

[0092] 5 Back glass panel

[0093] 6 EVA layer

[0094] 7 Sealing layer

[0095] 8 Cover band

[0096] 9 Membrane

[0097] 10 Membrane-side surface

[0098] 11 Transport belt

[0099] 12 Surface area

[0100] 13 Photovoltaic module

[0101] 14 Bubble

[0102] 15 Force distributing element

[0103] 15a Force distributing element

[0104] 15b Force distributing element

[0105] 15c Force distributing element

[0106] 16 Carrier web

[0107] 17 Panel-shaped section

[0108] 18 Support segment

[0109] 18a Support segment

[0110] 18b Support segment

[0111] 19 Lamination stretching frame

[0112] B Area

[0113] R Edge

[0114] P Point