CH701184A1 - Method of manufacturing a solar panel. - Google Patents

Abstract

The invention relates to a method for producing a solar panel (1) constructed from layers, wherein at least one layer (2) is preheated and brought together under vacuum or inert gas atmosphere with a layer structure (6) from the other layers of the solar panel and pressed therewith.

Description

The invention relates to a method for producing a solar panel made up of layers.

The invention further relates to a device for producing a solar panel constructed from layers, the device having a working chamber that can be evacuated and / or filled with a protective gas.

In the manufacture of solar panels, a sandwich structure is usually built under essentially normal room conditions. This sandwich construction has a glass plate as carrier material, a first layer of plastic film placed on the glass plate, on which a network of solar cells is placed, and a second layer of the plastic film covering the solar cells, on which a cover film is placed. The first * and the second layer of the plastic film, between which the solar cells are embedded, can be designed, for example, as an EVA film. The cover film, also referred to as a “backsheet”, can be formed, for example, from a weather-resistant plastic that is non-transparent in the visible spectral range, for example from a PVDF-PET-PVDF laminate. After the sandwich construction has been built up manually, it is inserted into a laminator. The laminator usually has a lower part with a heating plate and an upper part with a pressure membrane and thus essentially represents a heating / cooling press. The pressure membrane has a dual function. On the one hand, it serves to seal the working chamber airtight. On the other hand, the pressure membrane exerts a predetermined contact pressure on the layers of the solar module that are to be connected to one another. The space between the heating plate and the pressure membrane can usually be evacuated. The sandwich construction is placed with the glass plate at the bottom in the laminator so that it is heated by the heating plate. The glass plate is heated to the required temperature during the lamination process in order to ensure good crosslinking within the EVA films and with the glass plate and the grid of photovoltaic cells.

However, the invention is not limited to laminators. It can also be used in other procedures, e.g. Curtain casting or injection molding are used.

When placed directly on the heating plate, the glass plate can bulge up or down (encode) at its edges, so that there is an inhomogeneous temperature distribution of the sandwich construction. The temperature at the edges of the glass plate can be higher or lower than in its center, depending on the curvature of the glass plate. The entire heating process is delayed by the resulting distance between the edges or the center of the glass plate from the heating plate, since it takes a relatively long time for the glass plate to have the required temperature also in its areas curved away from the glass plate. In order to avoid warping of the glass plate, the sandwich construction can therefore be mounted on pins protruding from the heating plate, whereby a more homogeneous heating of the glass plate can be achieved.

As soon as the sandwich structure is at the melting temperature, which (depending on the glass thickness and sandwich structure) is the case after about 7 minutes, a pressure is generated from above by means of the membrane to ensure good temperature transfer and EVA crosslinking and a good connection of the individual layers. The pressing process now taking place at a pressure of approx. 1 bar, which also takes approx. 7 min. takes place under negative pressure or vacuum in the working chamber of the laminator in order to avoid inclusion of air bubbles. The glass plate is heated further during the pressing process. The heating and pressing process that takes place in the laminator is referred to as lamination. When laminating, for example, when EVA films are used, the previously milky EVA films form a clear, three-dimensionally cross-linked and no longer meltable transparent plastic layer in which the solar cells are now embedded and which is firmly connected to the glass pane and the back sheet. After pressing, the sandwich construction is cooled under pressure in a cooling press.

A disadvantage of the prior art is primarily the relatively long residence time of the sandwich construction in the laminator caused by the necessary heating of the glass plate. This results in relatively long throughput times and a severe restriction in the number of solar panels that can be produced with a laminator. Basically, by heating the glass plate before building the sandwich and inserting it into the laminator, the dwell time in the laminator could be significantly reduced. However, considerations that had to do with heating the glass plate before building the sandwich were always rejected, since the foils used to build up the plastic layer encapsulating the solar cells, for example EVA foils, can melt and form bubbles when they are placed on the glass plate. whereby the EVA foils can no longer be handled.

[0008] It is therefore the object of the invention to increase the productivity that can be achieved with a laminator and thus to increase its economic efficiency.

This object is achieved according to the invention with a method of the type mentioned at the outset in that at least one layer is preheated and brought together with at least one other layer of the solar panel in a vacuum or protective gas atmosphere.

The term “brought together” is understood here to mean that the preheated layer is only brought into contact with at least one of the other layers for the construction of the solar panel under vacuum. Before the vacuum is produced, the preheated layer is thus spatially spaced from the other layers.

Since the preheated layer, for example a glass, FRP or ceramic plate, has a layer structure, i. can be pressed with the other layers of the solar panel that have already been built up and arranged accordingly, the problems associated with placing foils, for example EVA foils, on a hot glass plate are avoided. Thus, the solution according to the invention enables a layer structure in which all layers of the solar panel do not have to be built on top of and adjacent to one another before pressing, but the layer structure of the other layers of the solar panel occurs separately from the preheated layer. The preheated layer is only brought together with the layer structure under vacuum or under a protective gas atmosphere, i.e. brought into contact with this, and optionally pressed with the layer structure. According to the invention, the sandwich construction no longer has to be built up in front of the laminator, but can also take place in it. By combining and pressing under vacuum, gas inclusions in the solar panel can be prevented in a very efficient manner and components in the air that cause corrosion of the solar cells, such as O2 and H2O, can be removed.

It is a merit of the invention to enable the heating of a layer of the solar panel even before it is introduced into the laminator and thus to reduce the length of time the layer structure remains in the laminator by the duration of the heating. By preheating the layer, even if it is heated further in the laminator, it is also possible to avoid encoding of the layer in the case of a glass plate in the laminator. Due to the solution according to the invention, the utilization of the laminator can be significantly improved. At this point, however, it should also be pointed out that the layer can also be heated in the laminator before it is brought together with the other layers.

According to an advantageous variant of the invention, the protective gas atmosphere can be realized with a protective gas which is soluble in a plastic layer which seals a photovoltaic layer, and the heated layer is pressed with the layer structure in this protective gas atmosphere. “Photovoltaic layer” is understood here to mean both a photovoltaic layer connected to a carrier material, for example glass, and also photovoltaic cells themselves.

A variant of the invention, which enables an even higher throughput or makes it possible to dispense with heating within the laminator or the lamination press, is that a material used to produce the preheated layer is the material with the greatest heat capacity materials used to make the layers. In this way, the storage of heat in the preheated layer can be implemented in a simple manner.

The manufacturing process can be simplified in that the preheated layer forms an outer cover layer of the solar panel. Due to the high heat capacity that can be achieved, it has been found to be particularly advantageous that the at least one preheated layer is formed from ceramic or glass.

A very favorable development of the invention provides that the material of the at least one preheated layer is brought to a temperature during the preheating that is greater than the melting temperature of at least one of the materials of the other layers. With this embodiment of the invention, it can be achieved in a simple manner that the temperature required for a lamination process can be reliably reached without an additional heating device in the lamination press even if the heated layer is transported for a long time to a lamination press. In this context, it is particularly advantageous if the preheated layer is heated to at least 10, preferably at least 15 or 20% of its phase transition temperature during the preheating. Typically the

An advantageous possibility of preheating the layer is that preheating takes place by immersing the layer to be preheated in a heat bath. If the layer to be preheated, for example made of glass or ceramic, is heated in a bath with a hot liquid, this is preferably done before washing. The composition of the liquid is advantageously chosen so that the cleaning is supported or the liquid can at least be easily removed.

Advantageously, the layer structure of the solar panel can have a transparent, solar cells encapsulating plastic layer in a finished state of the solar panel and a cover film, wherein at least one first film layer provided for producing the plastic layer is arranged on the cover film to produce the layer structure, the first Foil layer, the solar cells are applied, which are covered with at least one further foil layer provided for the production of the plastic layer, the preheated layer, for example a glass or ceramic plate, being preheated outside the laminator and pressed against the at least one further foil layer inside the laminator with the layer structure to connect the individual layers of the solar panel together.

A particularly short dwell time of the layer structure in the laminator can be achieved in that the preheated layer, in particular a glass or ceramic plate outside the laminator, is preheated to a temperature necessary to connect the film layers to the plastic layer and to the cover film and the glass plate .

The individual components, first layer of the plastic film of the layer encapsulating the solar cells, the second layer of the plastic film of the layer encapsulating the solar cells and the cover film can be unwound from rolls and guided into the laminator. The photovoltaic cells can be placed directly in the laminator between the first and second layers of plastic film of the layer that encapsulates them. Alternatively, the solar cells can also be placed outside the laminator and this structure can be transported into the laminator.

To build up the layer structure, the cover film can be provided as the first layer, then one layer of the plastic film can follow the layer encapsulating the solar cells, photovoltaic cells can be connected to this, then another layer of the plastic film follows the layer encapsulating the solar cells, on which the heated layer, in particular a glass or ceramic plate, is then applied. Since the heated layer is pressed onto the layer structure that has already been built up, the formation of bubbles can be avoided, as would happen if the individual film layers were placed on a hot glass plate. In addition, for example, an EVA film placed on the hot glass plate could no longer be handled properly as a result of the crosslinking with the glass surface.

A particularly high production speed can be achieved in that the cover film and the individual film layers provided for producing the plastic layer are wound into rolls stored outside the laminator, from which film webs are unwound and guided through the laminator.

In order to avoid damage to the solar cells very efficiently, the solar cells in the laminator can be placed on the at least one first film layer provided for producing the plastic layer. The solar cells can, however, also be placed between the film layers of the encapsulating plastic layer in front of the laminator, whereby the utilization of the laminator can be further improved.

In connection with the achievement of a high production speed with the simultaneous implementation of a simple structure, it is particularly advantageous if the cover film is used as a transport film for components of the solar panel arranged over it. For this purpose, the transport film can e.g. have holes on opposite edges into which gears rotating in the feed direction can engage.

The production process can be further optimized by ejecting the still hot solar panel from the laminator after lamination and cutting off the subsequent film webs of the cover film and the film layers provided for producing the plastic layer outside the laminator in the feed direction of the ejected solar panel.

An embodiment which further optimizes the entire production process provides that, before the film webs are cut, the solar panel on the cover film serving as a transport film is transported further to at least one location at which the solar panel is subjected to at least one further processing step.

A further embodiment provides that the individual film layers of the layer structure are arranged in the laminator in an already precut form. It can also be provided that the materials used are placed smaller than the preheated layer, for example a glass or ceramic plate, in order to avoid subsequent edge cutting.

According to a further variant, it can be provided that the layer structure has two glass or ceramic plates as the outer cover layers, as well as at least one first and at least one second film layer intended for the production of a plastic layer encapsulating solar cells, wherein between the first film layer and the The solar cells are arranged on the second film layer, the glass or ceramic plate preheated outside the laminator being applied to the at least one second film layer provided for producing the plastic layer and being pressed with the layer structure.

Another embodiment is that the layer structure has a coated with a photovoltaic layer glass or ceramic plate or an uncoated glass or ceramic plate and at least one provided for covering the photovoltaic layer film layer, which in a finished state of the solar panel a Forms a plastic layer that seals the photovoltaic layer, the uncoated glass or ceramic plate or the glass or ceramic plate coated with the photovoltaic layer being preheated and then applied to the at least one film layer and pressed with the layer structure.

According to a further variant, the glass plate can be coated with a photovoltaic layer and the layer structure can have a cover film and at least one film layer provided for covering the photovoltaic layer, which in a completed state of the solar panel forms a plastic layer that seals the photovoltaic layer, the preheated glass plate is applied to the at least one film layer and pressed with the layer structure.

The above-mentioned object can also be achieved according to the invention with a device of the type mentioned at the beginning in that the working chamber has means for combining at least one heated layer with at least one other layer.

According to an advantageous development of the invention, the working chamber can be designed as a pressing chamber, at least one holding device for a base plate of the solar panel being arranged in the pressing chamber, by means of which the base plate is held in a state brought to a predefined temperature and by at least one side wall the pressing chamber is spaced apart, wherein the base plate and / or the side wall are movable relative to one another. The heated base plate, for example a glass or ceramic plate, can be held by the holder and spaced from the other layers in the pressing chamber until the pressing chamber is evacuated and the heated base plate is desired to be brought together with the other layers.

The holding device can, for example, have supports for the base plate which can be lowered in the direction of the side wall. In this way, a good support of the base plate and a safe and defined lowering onto the other layers located in the pressing chamber of the device can be ensured.

A particularly advantageous further development of the device according to the invention provides that the holding device has a suction device for generating a negative pressure between the base plate and an upper side wall, preferably a cover, of the press chamber on which the base plate rests. In this way, before the base plate and the other layers are brought together, the base plate can be fixed in a defined position, essentially without mechanical holders. Regardless of this, however, at least one securing device can be provided in the pressing space for catching the base plate if it falls from the suction device.

According to a favorable variant of the invention, recesses for seals are provided in the upper side wall, preferably a cover, of the press chamber, the recesses surrounding areas of different sizes and channels for sucking air open into the areas of different sizes. This variant of the invention has the advantage that base plates of different sizes and weights can be easily held by the suction device, since the size of the area to be evacuated can be easily determined and adapted to the size of the base plate by inserting the seals into the corresponding recesses .

Another very favorable development of the device according to the invention provides that a cover of the pressing chamber can be moved against a lower part, with at least one elastic seal being provided between the cover and the lower part. This embodiment of the invention makes it possible to dispense with a pressure membrane or a pressure ram reaching into the interior of the press chamber for generating the required lamination pressure. The required lamination pressure on the layer structure is achieved by lowering the lid.

Replacing the seal, which can be designed as a wear part, is facilitated by the fact that the seal is fastened in a replaceable manner in a receptacle in the cover.

Automation of the production process is supported in that the laminator i. the device has a specially provided opening for inserting the heated base plate.

The device can be evacuated or alternatively has at least one inflow opening and at least one outflow opening for a protective gas.

The invention together with further advantages is explained in more detail below with reference to some non-limiting exemplary embodiments, which are shown in the drawings. These show schematically and not true to scale: FIG. 1 <sep> the layer structure of a solar panel; 2 shows a device according to the invention; 3 shows a device according to the invention from FIG. 2 in more detail; 4 shows an embodiment variant of the invention in which a heated base plate introduced into the working chamber or the pressing chamber of the device according to the invention is supported; FIG. 5 shows a plan view of a cover film of the solar panel as it can be used in the device according to FIG. 2; 6 shows a second variant of a device according to the invention; 7 shows an upright arrangement of a base plate with a layer structure, the glass plate being pressed with the layer structure by exerting pressure on the side; 8 shows a horizontal arrangement of the base plate and the layer structure from FIG. 7, the glass plate being pressed with the layer structure by exerting pressure from below in the direction of the layer structure; 9 shows a further embodiment of the invention, in which a base plate is pressed with a layer structure also having a base plate; 10 shows a variant of the invention with a carrier plate coated with a photovoltaic layer and a further cover plate, a further layer for sealing the photovoltaic layer and for connecting the plates being arranged between the plates; 11 shows a variant of the invention with a carrier plate coated with a photovoltaic layer, which is pressed with a layer structure consisting of foils; 12 shows a further embodiment of a device according to the invention; 13 shows a further variant of a device according to the invention, in which a suction device for a base plate of the solar panel is arranged in a cover of a vacuum chamber; FIG. 14 <sep> the inside of the cover from FIG. 13 in more detail; 15 shows the variant of the invention from FIG. 14 with a seal inserted in a recess in the cover, the space between the base plate and the cover not yet being evacuated or not yet completely evacuated; 16 shows the variant of the invention from FIG. 15, in which the space between the cover and the base plate is evacuated; 17 shows the variant of the invention from FIG. 15 with a closed, but not yet evacuated, vacuum chamber; 18 shows the variant of the invention from FIG. 17 with a closed and evacuated vacuum chamber; 19 shows a further variant of the invention with a closed but not yet evacuated vacuum chamber; FIG. 20 <sep> the variant from FIG. 19 with a closed and evacuated vacuum chamber; FIG. 21 <sep> shows a closed, but not yet evacuated, vacuum chamber of a device according to the invention (left part of FIG. 21) and the same device with a closed and evacuated vacuum chamber (right part of FIG. 21); FIG. 22 <sep> the device according to the invention from FIG. 17; 23 shows the device according to the invention from FIG. 22 in a closed and evacuated state; 24 shows a further variant of the device according to the invention; 25 shows yet another variant of the device according to the invention, in which a cover film is arranged between the cover of the vacuum chamber and the base plate; 26 shows a detail of the variant of the device according to the invention shown in FIG. 25; 27 shows another variant of the device according to the invention; 28 <sep> with a conveyor belt arranged between a lower part of the vacuum chamber and a layer structure; 29 shows a top view of the conveyor belt according to a first variant of the device according to the invention from FIG. 28; 30 shows a top view of the conveyor belt according to a second variant of the device according to the invention from FIG. 28; 31 shows a further variant of a device according to the invention with a base plate and a layer structure which is still completely separate from this and extends over the base plate; 32 <sep> the variant from FIG. 31 with a layer structure partially in contact with the base plate and a conveyor belt partially removed from the layer structure, and FIG. 33 <sep> the variant from FIG. 32 with a layer structure completely in contact with the base plate and conveyor belt completely removed from the layer structure

At the outset, it should be noted that in the differently described embodiments, the same parts are provided with the same reference numerals or the same component names, and the disclosures contained in the entire description can be transferred analogously to the same parts with the same reference numerals or the same component names. The location details chosen in the description, such as above, below, to the side, etc. refer to the figure immediately described and shown and are to be transferred accordingly to the new position in the event of a change in position. Furthermore, individual features or combinations of features from the different exemplary embodiments shown and described can also represent independent, inventive or inventive solutions.

Fig. 1 shows a cross section through a solar panel 1, as it can be produced with the present invention. The solar panel 1 has a layered construction with a base plate 2, for example a glass plate, and a plastic layer 4 that is transparent and encapsulates solar cells 3 after the solar panel has been laminated, as well as a cover film 5. The glass plate 2 serves as a carrier layer for the adjoining layer structure 6 consisting of the other layers of the solar panel 1. According to the invention, in order to produce the solar panel 1, the base plate 2 is preheated separately from the layer structure 6 and then with the layer structure 6 is pressed.

However, the invention is not restricted to the above-mentioned solar panel, rather all other types of solar panels can also be produced with the solution according to the invention. For example, further exemplary types of solar panels are shown in FIGS. 9 to 11, as they can be produced with the solution according to the invention. The invention is also not restricted to only preheating an outer cover layer, such as a glass or ceramic plate. Rather, one or even more of the other layers can also be preheated. It is only essential to the invention that the one or more preheated layers are only brought together with the other layers under vacuum. For example, it is possible to preheat several layers, the temperature of these layers, provided they touch each other before the working chamber is evacuated, should be below the melting temperatures of the individual materials in order to avoid undesired air inclusion. The materials should also not deform significantly, e.g. under the action of internal tensions.

According to FIG. 2, a device 7 according to the invention for producing solar panels 1 has a laminator 8 for connecting the individual layers of the solar panel 1. In this context, the laminator 8 is understood quite generally to mean that component in which the connection of the individual layers of the solar panel 1 takes place, the laminator 8 according to the invention not necessarily having to have a heater, as will be explained further below. Through the laminator 8, tracks of the cover film 5 of a first film layer 9 of the plastic layer 4 encapsulating the solar cells and a further film web 10 of the plastic layer 4 encapsulating the solar cells 3 can be guided. The film webs 5, 9, 10 can be unwound from rolls 11, 12, 13, wherein the film webs 9, 10 of the plastic layer 4 can be arranged over the cover film 5. The solar cells 3 can be placed in the laminator 8 or outside it between the film webs 9 and 10.

As an alternative to the above-mentioned embodiment with the film webs, the films 9, 10 and 5 can be brought into the laminator 8 already cut to size. This can be done manually or by machine. A pre-cut structure of foils 5, 9 and 10 as well as solar cells 3 on a carrier frame or a conveyor belt could thus also be introduced into the laminator 8.

Furthermore, the device can have a heater 14 arranged outside the laminator 8 for heating the base plate 2.

The base plate 2 can, however, also be heated in a vacuum chamber 15 of the laminator 8. At this point it should be noted that the terms “vacuum chamber”, “pressing chamber” and “working chamber” are used synonymously in this document. It is important that the heating takes place symmetrically so that the base plate (e.g. made of glass or ceramic) does not puff up. The chamber can be evacuated while it is heating. The material of the layer to be preheated can be heated in the following way: • <sep> by means of a heating plate, as known from normal laminators; • <sep> by means of EM radiation: infrared emitters, microwaves, lasers; • <sep> by means of ovens or baths in which the material lingers; • <sep> by means of electric fields, as known from high-frequency welding; • <sep> using heating mats, e.g. electrical; • <sep> inductive, electrical (heating coil); • <sep> by means of combustion: for example by means of a glass flame.

The above list is not exhaustive and merely exemplary in nature.

If the layer to be preheated is produced or treated (washed) on site, the temperature that it receives can be used.

If, for example, the base plate 2 is heated in a bath with a hot liquid, this is preferably done before washing the base plate 2. The liquid can be selected so that it supports cleaning or at least simply moves away from the base plate 2 again leaves.

As known from the prior art, the laminator 8 can have an upper part or cover 16 and a lower part 17, wherein the laminator 8 can be opened by moving the upper part, so that the working chamber 15, which is also described in this document is referred to as a press room or vacuum chamber, is accessible. The base plate 2 can be held on a cover that closes the pressing chamber by means of a holding device not shown in detail in FIG. As will be explained in greater detail below, the holding device can, for example, be designed as a suction device.

After the working chamber 15 has been evacuated, the pressing pressure required for the lamination can then be generated, for example by means of a press ram, after the base plate 2 has been lowered onto the other layers. The press ram can have a pressure plate 18 on which a press cushion can be arranged. This press cushion can accommodate tolerances. However, this can also be done with an EVA layer. The press pad can contain silicone and / or agents to increase the thermal conductivity, e.g. Metal particles. By making the press cushion compressible, the thermal conductivity can be increased. The cushion can comprise metal springs or steel wool. An increase in the thermal conductivity of the press cushion is particularly advantageous if a heater is arranged under the pressure plate 18 or if the pressure plate 18 itself can be heated.

It should be noted that the invention is not limited to the just mentioned structure of the laminator 8 or the device 7, so the laminator 8 can also consist of several levels of working chambers arranged one above the other.

Furthermore, a possibly provided robot for glass supply can also equip two laminators standing next to one another.

Furthermore, the laminator 8 can have a heating plate 19 which can be arranged under the cover film in order to enable the layer structure located in the laminator 8 to be further heated depending on the temperature of the preheated base plate 2. When using a heating plate 19, the cover film 5 is advantageously made from a heat-resistant plastic laminate. In this context, heat-resistant means that the cover film 5 is heat-resistant at least up to the maximum temperature generated by the heating plate 19 during lamination.

A single system can also be used to preheat the materials and allow the solar panels produced to cure. Typically the panels cure at a temperature 5%, 10% or more below the process temperature. For example, two chambers can be provided in an oven: one for preheating the base plates and one for the laminated modules. The temperature of the first chamber is typically higher than in the second chamber.

At this point, however, it should be pointed out that the arrangement of a heating plate 19 in the laminator 8 is not absolutely necessary to implement the approach on which the invention is based, since due to the high heat capacity of, for example, glass and ceramic materials, there is also the possibility if the preheated layer is made of such a substance that further heating within the laminator 8 can be dispensed with. Thus, it would be sufficient to simply introduce a base plate 2 heated to the temperature of approx. 150 ° C required for the lamination process into the laminator 8 and to press the base plate 2 against the film layer 9 by means of a pressing means, for example a membrane or the press ram

During a transport, the material of the preheated layer 2 can cool down. Cooling also occurs when the other materials, which are cooler, come into contact. The material of the preheated layer 2 can therefore be brought to a higher temperature in the course of the preheating than the minimum temperature required in the process in order to prevent excessive cooling. Laminating runs e.g. at around 180 degrees Celsius. Glass can e.g. B. can easily be heated to 200 degrees, 250 degrees or even higher in order to warm up the other materials. In the ideal case, the base plate 2 cools during lamination (gives off energy to other materials) to the minimum temperature required for lamination.

If enough energy can be stored in the material of the preheated layer 2 by preheating, the production of the solar panels 1 can take place without further heating or only with little heating (and therefore faster). For this purpose, the pressure plate 18 of the press ram or the heating plate can comprise an insulation layer so that the energy cannot flow there during lamination.

At this point it should be mentioned that the preheated layer 2 can be additionally heated or kept at temperature when it is introduced into the laminator 8.

In order that as much energy as possible can be stored in the material of the preheated layer 2 without its physical state changing, it can be heated to 50, 70 or 90% of the phase transition temperature of its material.

The phase transition temperatures of some important materials used in layer 2 are given in the table below:

The pressing of the hot layer 2 against the layer structure 6 lying beneath it takes place under vacuum in order to possibly remove corrosion of the solar cells and air constituents causing them from the working chamber 15 of the laminator 8. The formation of air bubbles in the layer structure is also better prevented by evacuating the working chamber 15.

According to another variant of the invention, however, instead of evacuating the working chamber of the laminator 8, a protective gas can be let into the latter so that the lamination process takes place under a protective gas atmosphere. If the foils 9 and 10 are EVA foils, for example, CO2 can be used as a protective gas, although other combinations of foils and gases are of course also possible, the protective gas being soluble in the foil material, e.g. PVB and CO2 or TPU (Thermoplastic Polyurethane) and CO2. In order to allow the protective gas to flow in and out of the working chamber of the laminator 8, it can have one or more inflow or outflow openings for the protective gas, denoted by the reference numerals 20 and 21 in FIG. 3, which can also be closed if necessary.

As shown in FIG. 3, instead of manually inserting the heated layer 2 into the laminator 8, the layer 2 can also be automatically inserted into the laminator 8. For this purpose, the layer 2 can be conveyed by the heating device 14, for example a conventional heating plate, via rollers 22 or a conveyor belt in the direction of the laminator 8. The laminator 8 can have an opening 23 for receiving the hot layer 2. The opening 23 is expediently arranged above an inlet 24 for the webs of the foils 5, 9, 10. On the side of the working chamber 15 of the laminator 8 opposite the opening 23, an outlet opening 25 for the laminated solar panel 1 and the film webs 5, 9, 10 can be provided. Both the opening 23 and the outlet opening 25 can be closed by means of appropriate covers, for example with a plastic, rubber or metal cover, so that after the layer 2 has been introduced into the working chamber 15 of the laminator 7, it can be closed and evacuated. If necessary, the inlet 24 can also be provided with a cover resting on the film webs 5 or 9.

In order to enable the layer 2 to be lowered in a controlled manner onto the film 9, the laminator 8, as shown in FIG. 4, can have supports 26 for the layer 2 which can be lowered in the direction of the plane of the cover film 5. These can be pins which can be sunk into bores 27 of a base plate 28, for example a heating plate, of the laminator 8. Before the layer 2 is introduced into the laminator 8 through the opening 23, the pins can be extended so that the layer 2 comes to rest on the pins. The working chamber 15 of the laminator 8 can then be evacuated and the pins lowered. After the working chamber 15 has been evacuated, pressing can then take place. A corresponding arrangement of the pins inclined to the longitudinal center line of the layer 2 or the foils 9, 10, 5 allows the layer 2 to be lowered to the level of the topmost foil layer 9 without the foils 9, 10, 5 penetrating through the Pens is required. The pins can be lifted out of the base plate 28, for example by means of hydraulic rams not shown here, and sunk into it again. It would also be possible to load the pins with appropriately dimensioned helical springs arranged below them, wherein the downward movement of the layer 2 can be initiated by the pressing means used, for example a membrane. According to another embodiment of the invention, it would also be possible to arrange the pins perpendicular to the base plate 28, but depending on the dimensions of the layer 2 and the foils 9, 10 and 5, it may be necessary for the foil layers 9, 10 and 5 to be penetrated by the pins . For this purpose, the foils 9, 10 and 5 can have corresponding perforations. An alternative solution to using pins as a support 26 for the layer 2 could, for example, also be provided with a frame that can be lowered in the direction of the base plate 28.

Furthermore, it can be provided to suck the preheated layer 2 on the upper part or cover 16 of the laminator 8 or to temporarily fix it there by generating a vacuum and then to let the layer 2 fall onto the layer structure below and with the Start pressing.

According to FIG. 5, the individual film layers 9, 10 as well as the hot solar panel 1 can be transported out of the laminator 8 by means of gears 30, 31 which engage in holes 29 on the edges of the cover film 5 and rotate in the feed direction. The cover film 5 serves as a transport film.

After the lamination process has ended, the solar panel 1, which is still hot, is ejected from the laminator 8 and processed further in subsequent steps, and the individual (film) layers 4a, 4b and 5 are cut off outside the laminator 8. The cutting of the foils 9, 10 and 5 can again take place manually or automatically, for example by means of automatic scissors or knives. The solar panel 1, which is still hot, is advantageously transported on the transport film to a location where it is subjected to the next processing step.

As shown in FIG. 6, the preheated layer 2 in the laminator 32 can also be pressed from below onto the layer structure or against the film layer 9, the sequence of the film layers remaining the same when viewed from the direction of the layer 2, as in FIG the embodiment of the invention shown in FIGS. 2 and 3, that is, first the film layer 9, then the solar cells 3, which are covered by the film layer 10 and the cover film 5. In the embodiment shown here, the preheated layer 2 can be pressed against the layer structure 6 by means of a pressing means 33, for example by means of a press ram.

According to FIG. 7, the preheated layer 2 and the layer structure 6 can also be arranged upright or at an angle, pressure being exerted from the direction of the glass plate 2 and / or also from the direction of the layer structure 6.

FIG. 8 shows a variant of the invention in which the arrangement of the preheated layer 2 and the layer structure 6 corresponds to the arrangement from FIGS. 2 and 3. In contrast to the variant of the invention shown in FIG. 2, however, the pressure is not exerted from above from the direction of the layer 2, but from below from the direction of the layer structure 6.

According to FIG. 9, the layer structure 34 can have a glass or ceramic plate 35 as well as a first and a second film layer 9, 10 provided for producing a plastic layer 4 encapsulating solar cells 3. As in the embodiment according to FIG. 2, the solar cells 3 are arranged between the first film layer 9 and the second film layer 10. The layer 2, preheated outside the laminator, is placed against the film layer 9 inside the laminator and pressed with the layer structure 34. Here, too, pressure can be exerted from the direction of the glass plate 2 and / or from the direction of the layer structure 34.

At this point it should be mentioned that in all of the above-mentioned embodiments, in addition to the above-mentioned film layers and layers, further intermediate layers can be provided, for example a fleece lying on the non-photoactive side of the solar cells 3.

As shown in FIG. 10, the layer structure 34 can have a glass plate 37 coated with a photovoltaic layer 36 and a film layer 9 provided to cover the photovoltaic layer 36. The film layer 9 can be embodied, for example, as an EVA film which, when the solar panel is in a finished state, forms a plastic layer that seals the photovoltaic layer 36. Alternatively, instead of the coated glass plate 37, the layer structure 38 could be formed by an uncoated glass plate 39 and the film 9, in which case the coated glass plate 37 would be preheated.

Depending on whether the layer structure 38 contains the glass plate 39 or the coated glass plate 37, either the glass plate 39 or the glass plate 37 coated with the photovoltaic layer 36 can be preheated outside the laminator and then applied to the at least one film layer 9 and with the layer structure 38 are pressed.

In principle, however, it would also be possible to preheat both glass plates 37, 39 outside the laminator and to press them simultaneously with the layer 9 arranged between them inside the laminator. This possibility is given in particular when a standing arrangement of the glass plates 37, 39 is selected in the laminator and the film 9 is hung between the two glass plates 37, 39. The term “layer structure” is to be interpreted in such a way that it means an arrangement of the individual layers inside or outside the laminator that enables the individual layers to be pressed together. I.e. the layers of the layer structure 6, 34 or 38 can be arranged next to one another or on top of one another that, assuming the appropriate temperature, they can be connected to one another by pressing in the laminator, the layers of the layer structure 6, 34 or 38 before Pressing does not necessarily have to lie against one another. This applies in particular to a standing or hanging arrangement of the individual layers.

According to FIG. 11, the layer structure 38 can have the cover film 5 as well as the film layer 9 provided for covering the photovoltaic layer 36 of the glass plate 37. The preheated glass plate 37 is placed against the film layer 9 and pressed with the layer structure 38, it being possible for the pressure to be exerted from the direction of the glass plate 37 and / or from the direction of the layer structure 38.

As shown in FIG. 12, the materials can be introduced into the laminator 8 for the production of solar panels 1 by means of different transport means.

The heated layer 2 or base plate can be moved into the laminator 8 on a slide 40 (left). According to this example, it is lifted from the carriage 40 by a suction cup with almost the size of the plate. After the carriage 40 has moved away from the laminator 8, a conveyor belt 41 moves the layer structure 6 from the other layers to the correct location. The suction cup moves down and closes the vacuum chamber.

Hot parts (glass, ceramic or the module produced) can also be processed on one side of the laminator and the other materials on the other side. This allows dangerous areas to be better protected. Since the laminated module has to stay for a while so that the crosslinking can take place in the laminate, the module can be fed back into the furnace, where the base plate, for example made of glass or ceramic, has been preheated.

According to FIG. 13, the preheated base plate 2 can be gripped or raised by means of a vacuum (suction cup and channels 42) or mechanically by means of a slide 43. In the example shown, the slide 43 is automatically pushed to the side when the cover 16 moves downwards.

As shown in FIG. 14, recesses 44 can be formed in the cover 16 so that base plates 2 of different sizes can be held between a base plate 2 to be held and the cover 16 by generating a negative pressure. A seal, for example a rubber, is inserted into one of the recesses 44 that best corresponds to the size of the glass plate 2. The plate 2 and this seal form a suction cup which can be evacuated through the channels 42 in order to suck the plate 2.

As can be seen from FIGS. 15 and 16, the seal inserted into one of the recesses 42 can advantageously comprise a lip. When the base plate 2 is held against the lips, and at the same time the air is sucked out (FIG. 15), the base plate 2 is pressed against the cover 16 (FIG. 16).

According to FIGS. 17 and 18, the base plate 2 is advantageously held rigidly by the cover 16, the vacuum chamber 15 closing when the cover 16 is moved in the direction of the lower part 17. The vacuum can only be generated when the chamber 15 is closed. Until the vacuum is generated, the base plate 2 should not yet rest on the other layers 6, because otherwise air can be trapped. Once the vacuum has been reached, the cover 16 can be lowered further and the base plate 2 and the other layers 6 come into contact with one another.

It is advantageous that a seal 45 is provided between the cover 16 and the lower part 17, which closes the vacuum chamber 15 during evacuation, but can also be elastically deformed when the cover 16 is moved down without being damaged when this process is repeated many times at high temperatures. The seal 45 can e.g. consist of a plastic or metal. In the first case it can be made inflatable. The pressure in seal 45 may e.g. be kept constant when moving the cover 16 down. This ensures that there is a good seal without unnecessarily stressing the material of the seal 45.

Systems are also conceivable in which the shape of the seal 45 does not change significantly when it is moved down, as shown for example in FIGS. 19 and 20.

It is advantageous if the seal 45 is located at the top of the cover 16, as in FIG. 21, so that it is not soiled and the base plate 28 or the lower part 17 can be cleaned more easily. In the ideal case (not shown) the lower part 17 is designed to be flat. In FIG. 21, the seal 45 is tubular and attached to the cover 16. The left part of FIG. 21 shows the device with a not yet lowered cover 16, while the right part of FIG. 21 shows the device with a lowered cover 16 and a compressed seal 45.

Since the seal 45 is a wearing part, it should be easy to replace. For this purpose, the seal 45 can be snapped onto the cover 16 or at least can be easily removed.

If the seal 45 is designed to be inflatable, as shown in FIG. 22, the connection to the air pressure system should also be easily detachable.

As can be seen from FIG. 23, the plastic layers are liquefied during lamination and can escape on the side of the laminate and contaminate the cover 16. This happens because gases can escape from the materials in the layer structure 6, which cause the liquefied materials to foam.

The simplest measure to prevent foaming consists in breaking the vacuum in good time. This can, but does not have to, cause gases to remain in the laminate and possibly form bubbles.

The contamination of the cover 16 and the lower part 17 can be counteracted by providing recesses 46 in the cover 16, as shown in FIG.

Furthermore, as shown in FIGS. 25 and 26, a cover sheet 47 can be provided on the cover 16 to avoid contamination. This cover sheet 47 is arranged at least in sections between the base plate 2 and the cover 16.

As can be seen from FIG. 26, however, the cover sheet 47 advantageously does not extend inside the suction cup, but only over the edges of the base plate 2, where contamination is to be expected. The cover sheet 47 can be attached to the cover 16 and can be easily replaced. The seal of the suction cup and the cover sheet 47 can also form a part which may move with the panel out of the pressing chamber after lamination.

It can furthermore be advantageous if the unheated materials are introduced into the laminator 8 on a conveyor belt 48 or transport sheet, as is known from conventional laminators.

As also shown in FIG. 27, the layer structure 6 can be introduced onto the conveyor belt 48 into the vacuum chamber. It can hardly be avoided that the layer structure 6 adheres to the conveyor belt 48 during lamination.

So that the module can be easily detached from the conveyor belt 48 after lamination, a cover sheet or a cover film can be provided that adheres less to the layer structure 6 than the conveyor belt 48 and / or is easier to clean or with the module is transported away to later, e.g. when the materials of the layer structure 6 have hardened to be removed.

In order to be able to better seal the vacuum chamber 15 when using a conveyor belt 48, a soft sealing element 49 or a recess in the base plate 28 (not shown) can be arranged opposite the seal 45 on the lower part 17 of the laminator 8, as shown in FIG Fig. 28 is shown. This soft sealing element 49 interacting with the seal 45 can be arranged below the conveyor belt 48, so that the conveyor belt 48 runs between the seal 45 and the soft sealing element 49. The additional sealing element 49 results in a better sealing of the vacuum chamber 15 when the conveyor belt 48 is used. This additional sealing element 49 can be flush (left) or protrude (right).

If the layer structure 6 is transported on the conveyor belt 48 into the vacuum chamber 15, the conveyor belt 47 can extend beyond the vacuum chamber 15 on two (FIG. 29) or four (FIG. 30) sides, depending on its design and width extend.

The conveyor belt 48 can furthermore comprise at least one depression into which the materials of the layer structure 6 just fit in terms of size. The position of these materials or layers is precisely defined. As a result, e.g. Overhangs can be avoided or reduced. Markings can also show where the materials are to be placed on the conveyor belt 48. The recess can support the sealing of the pressing chamber.

As shown in FIGS. 31-33, the preheated base plate 2 can also be located below the layer structure 6. The remaining, generally flexible layers can then be positioned in the correct position on a conveyor belt 50 above the base plate 2 (FIG. 31).

The conveyor belt 50 must then be removed without the layer structure 6 shifting. This can e.g. done in that the conveyor belt 50 is pulled to the side (in Fig. 32 to the left, while the layer structure 6 is held, for example by means of a clamp, or pressed in some places on the hot base plate 2. In both cases, enough friction can be achieved to prevent the layer structure 6 from moving along with the conveyor belt 50. In the second case, the conveyor belt 50 must have a recess to enable the layer structure 6 to be pressed down onto the hot base plate 2 during the removal of the conveyor belt 50. This must all be done under vacuum or a protective gas atmosphere, because otherwise air pockets can arise In order to save space, the means of transport 50 can be rolled up.

The variant of the invention shown in FIGS. 31-33 is particularly suitable for the production of glass-glass modules, that is to say modules which have a glass plate as the first and last layer. In this case a second glass plate is held on the lid, e.g. as shown in Figs. 15-20.

In summary, it can be said that the solution according to the invention significantly reduces the dwell time of the sandwich construction in the laminator and the cycle time.

In conclusion, it should be noted that the exemplary embodiments only show possible design variants of the solution according to the invention, the invention not being restricted to the specifically illustrated design variants. In particular, combinations of the individual design variants with one another are also possible, these possible variations being within the ability of a person skilled in the art based on the teaching of the technical action of the present invention. The scope of protection as defined by the claims also encompasses all conceivable design variants that realize the solution concept underlying the invention and are not explicitly described or shown or are possible through combinations of individual details of the shown and described design variants. The protection also extends to the individual components of the device according to the invention, insofar as they are essential for realizing the invention.

List of reference symbols

1. <sep> solar panel 2. <sep> preheated layer 3. <sep> solar cells 4. <sep> plastic layer 5. <sep> cover film 6. <sep> layer structure 7. <sep> device 8. <sep > Laminator 9. <sep> Foil layer 10. <sep> Foil layer 11. <sep> Roll 12. <sep> Roll 13. <sep> Roll 14. <sep> Heater 15. <sep> Press room 16. <sep> Lid 17. <sep> lower part 18. <sep> pressure plate 19. <sep> heating plate 20. <sep> inlet opening 21. <sep> outlet opening 22. <sep> rollers 23. <sep> opening 24. <sep> inlet 25. <sep> Outlet opening 26. <sep> Supports 27. <sep> Holes 28. <sep> Base plate 29. <sep> Holes 30. <sep> Gear wheel 31. <sep> Gear wheel 32. <sep> Laminator 33. <sep > Pressing means 34. <sep> Layer structure 35. <sep> Glass plate 36. <sep> Photovoltaic layer 37. <sep> Coated glass plate 38. <sep> Layer structure 39. <sep> Uncoated glass plate 40. <sep> Slide 41. < sep> conveyor belt 42. <sep> channels 43. <sep> slider 44. <sep> recesses 45. <sep> sealing 46. <sep> recess 47. <sep> cover sheet 48. <sep> conveyor belt 49. <sep> Sealing element 50. <sep> conveyor belt

Claims (17)

1. A method for producing a layered solar panel (1), characterized in that at least one layer (2) is preheated and brought together under vacuum or inert gas atmosphere with at least one other layer (6, 34, 38). 2. The method according to claim 1, characterized in that the protective gas atmosphere with a in a photovoltaic layer (3, 36) sealing the plastic layer (4) soluble protective gas is realized. 3. The method according to claim 1 or 2, characterized in that a material used for producing the preheated layer (2) material is the material with the greatest heat capacity of the materials used for the production of the layers (5, 9, 10). 4. The method according to any one of claims 1 to 3, characterized in that the preheated layer (2) forms an outer cover layer of the solar panel (1). 5. The method according to any one of claims 1 to 4, characterized in that the at least one preheated layer (2) is formed of ceramic or glass. 6. The method according to claim 5, characterized in that the material of the at least one preheated layer (2) is brought in the preheating to a temperature which is greater than the melting temperature of at least one of the materials of the other layers (5, 9, 10) , 7. The method according to any one of claims 1 to 6, characterized in that a preheating by dipping the preheated layer (2) takes place in a heat bath. 8. The method according to any one of claims 1 to 7, characterized in that the preheated layer (2) is heated in the preheating to at least 10%, at least 15% or 20% of its phase transition temperature. 9. Device (6) for producing a built-up of layers solar panel (1) according to a method according to one of claims 1 to 8, wherein the device comprises an evacuable and / or filled with a protective gas working chamber (15), characterized in that the Working chamber (15) comprises means for merging at least one heated layer with at least one other layer. 10. The device according to claim 9, characterized in that the working chamber (15) as a pressing chamber for pressing a layer structure (6, 34, 38) of a plurality of layers (5, 9, 10) of the solar panel (1) is formed, and in the pressing chamber at least one holding device for a base plate (2) of the solar panel is arranged, through which the base plate (2) can be kept in a state brought to a predefined temperature, the base plate (2) and / or a side wall of the pressing chamber relative are movable relative to each other. 11. The device according to claim 10, characterized in that the holding device in the direction of the side wall lowerable supports (26) for the base plate (2). 12. The apparatus of claim 10 or 11, characterized in that the holding device is a suction device for generating a negative pressure between the base plate (2) and an upper side wall, preferably a cover (16), of the pressing space, on which the base plate (2) , having. 13. Device according to one of claims 10 to 12, characterized in that in the pressing space at least one securing device for catching the base plate (2) is provided upon release of the holding device. 14. Device according to one of claims 10 to 13, characterized in that in the upper side wall, preferably the lid (16), of the pressing space recesses (44) are provided for seals, wherein the recesses (44) circulate areas of different sizes and channels ( 43) lead to the extraction of gas in the areas of different sizes. 15. Device according to one of claims 9 to 14, characterized in that a cover (16) of the working chamber (15) against a lower part (17) is movable or vice versa, wherein between the lid (16) and the lower part (17). at least one seal (45), in particular an elastic seal, is provided. 16. The apparatus according to claim 15, characterized in that the seal (45) is replaceably mounted in a receptacle. 17 solar panel (1), characterized in that, it is prepared according to one of claims 1 to 8 and / or a device according to one of the claims 9 to 16.