DE102015115453A1 - Laminating device for laminating a layer stack and installation for producing photovoltaic modules - Google Patents

Abstract

The invention relates to a laminating device for laminating at least one layer stack 26 with at least one glass layer and at least one adhesive substance layer by means of pressure and heat. The laminating device comprises a lower part 17 and an upper part 18, which can be connected in a gas-tight manner to the lower part 17 or placed on it in order to form an openable and closable gas-tight working chamber 19 for the layer stack 26, a pressing element 20 arranged essentially within the working chamber 19 for applying a load necessary for lamination on the layer stack 26 and means 24, 25 for introducing a process heat necessary for lamination in the layer stack 26. The lamination essentially consists of a cassette 16, the at least the lower part 17, the upper part 18 and the pressing element 20 and the means 24, 25 for introducing the process heat and which can be transported along a conveying path 7 in order to be used for a plurality of process steps at different locations in the conveying path 7.

Description

The present invention relates to a laminating device for laminating at least one layer stack comprising at least one glass layer and at least one heat-activatable adhesive layer, by means of pressure and heat according to the preamble of claim 1. The invention further relates to a system for producing photovoltaic modules in several process steps along a conveying path , which comprises a laminating section for laminating at least one such layer stack, according to the preamble of claim 19.

A laminating device of the present type comprises a lower part and an upper part, which can be connected in a gas-tight manner to the lower part or can be placed on it in order to form an openable and closable gastight working chamber for the layer stack. Substantially within the working chamber, a pressing member is arranged to apply a ballast necessary for lamination to the stack of sheets. The laminating device is finally equipped with means for introducing a process heat necessary for laminating into the layer stack.

Such a laminator is preferably used for laminating photovoltaic modules under pressure and heat. Photovoltaic modules usually consist of a solar cell layer which is formed of a plurality of juxtaposed solar cells and their interconnection and which is arranged between a glass plate and a weatherproof film or between two glass plates. By means of one or mostly two layers of a heat-activatable adhesive, which are arranged in the layer stack between the solar cell layer and the glass plate and / or the weatherproof film, these individual layers of a photovoltaic module can be laminated together under pressure and heat, so that the solar cells and their electrical interconnection after curing or crosslinking of the Adhäsivstoffschicht moisture-tight and weatherproof are encapsulated in a translucent layer composite. In order to make the photovoltaic module long-term stable, frame members are then usually still attached, which cover the edges of the particular glass plate circumferentially, optionally also an additional edge seal is integrated into the frame.

In the prior art, such laminators are usually formed as a hydraulic press comprising a lower half of the press and an upper half of the press, which are movable relative to each other to open and close the press. The lower half of the press and the upper half of the press form a working chamber in the closed state by means of circulating, one- or multi-part seals, within which one or more layer stacks are laminated as workpieces. A flexible membrane divides the working chamber into an evacuable product space provided for receiving at least one workpiece and an evacuable and / or pressurizable pressure space. Due to a pressure difference in the working chamber created by evacuating the product space and / or by pressurizing the pressure space, the diaphragm is pressed against the workpiece, thereby directly or indirectly pushing the workpiece against a lower surface of the working chamber and thereby applying the load required for lamination to the workpiece ,

In order to laminate a work piece or several work pieces at the same time - for simplicity's sake, only one work piece will be discussed below - this is moved into the product space of the work chamber and the working chamber is closed. Then, at least the product space is evacuated normally.

At the latest when the product space of the press chamber has been evacuated to a desired pressure, which is generally below 1 mbar, the pressure space is vented, so that the membrane hangs up on the workpiece due to the pressure difference between the pressure chamber and the product space. By controlling the pressure in the pressure chamber, a desired contact pressure of the diaphragm is adjusted to produce the load required for lamination on the workpiece. Optionally, the pressure chamber is additionally pressurized thereto, for example by introducing compressed air.

An early evacuation, in particular of the product chamber of the working chamber - if possible even before a significant heating of the workpiece - allows any air bubbles (levy air between the workpiece layers) or possibly formed during heating gases are pulled out of the workpiece before hardening or crosslinking of the adhesive in the adhesive layer begins.

The process heat necessary for the lamination process is usually introduced into the workpiece by the fact that the underside of the vacuum chamber is designed as a heating plate, against which the workpiece is pressed through the membrane. The pressure and the process heat together then ensure the softening or activation of the adhesive layer and, if appropriate, their curing or crosslinking.

Such known presses for laminating photovoltaic modules are for example in the DE 10 2009 020 172 A1 , of the US 6,367,530 or in the EP 2 457 728 A1 described.

A plant for producing photovoltaic modules of the present type, with which the photovoltaic modules can be manufactured in several process steps along a conveying path, includes in the conveying path at least one laminating section for laminating at least one layer stack with a solar cell layer, at least one glass layer and at least one adhesive layer under pressure and Warmth. In prior art systems, this laminating section is formed by one or more laminating presses of the type described above, which laminate a corresponding stack of layers by means of pressure and heat to form a photovoltaic module semifinished product.

In general, such a system comprises upstream of the laminating section a plurality of sections in which the individual layers are laid to the layer stack, wherein optionally the solar cell layer is previously provided by laying the individual solar cells and electrically interconnecting them in line, and wherein, for example, a weatherproof backsheet tape fed and cut to size. Downstream of the laminating section, such sections are normally followed by further sections, in which frame sections are attached to the laminated layer stack and, if appropriate, provided with sealing material, are assembled into a frame. After setting a junction box, the photovoltaic modules are ready; Optionally, quality control and the packaging of the finished photovoltaic modules can take place downstream in line.

In the known systems for producing photovoltaic modules, the lamination devices contained therein are usually the slowest station in the entire production process. Thus, two or more conventional presses are often used to laminate the photovoltaic modules or, alternatively, a multi-ply press having a plurality of lamination devices on top of each other which are operated simultaneously.

In a production line, however, it is problematic that before the laminating station, the successively arriving stack of layers to be laminated must be collected and divided into batches on individual presses or individual press floors. After the laminating station, they must accordingly be brought together again in the common conveyor line and brought into a uniform row, which is also not optimal.

To increase the throughput in a laminating, it is for example from the EP 1 997 614 A2 become known to shorten the cycle times during lamination in that the actual lamination is divided into several steps, which are carried out in each case one of several successively arranged presses.

All of these approaches in the prior art, which shorten the processing time in the laminating to better utilize the other stations of a photovoltaic production line, have in common that increases the cost of the already elaborate laminating presses, possibly even be multiplied.

The present invention is therefore based on the object, a plant for the manufacture of photovoltaic modules and a lamination, which is suitable for use in such a system to propose, which are compared to the prior art easier and cheaper to implement.

This object is achieved by a laminating with the features of claim 1 and by a system having the features of claim 19. Advantageous embodiments of the laminating device according to the invention can be found in claims 2 to 18; Preferred developments of the system according to the invention are set out in claims 20 to 29. A preferred use of the laminating device according to the invention is defined in claim 30.

Accordingly, a laminating device according to the invention essentially consists of a cassette which essentially comprises a lower part, a top part which can be connected in a gas-tight manner to or can be placed onto the bottom part in order to form a gas-tight working chamber, a pressing element which is used to apply the load required for lamination within the working chamber is arranged, and means for introducing the necessary process heat includes. This cassette can be transported along a conveyor line in order to be used for several process steps at different locations in the conveyor line. The means for introducing the process heat can simultaneously act as a pressing element; these must therefore not be separate components.

The system according to the invention is characterized by a plurality of such inventively designed as transportable cassettes lamination, and also includes a conveyor system for transporting these cassettes at least by the laminating. The conveyor line and the conveyor system need not be formed linear in the context of the present invention be; it can also be, for example, a turntable concept.

The present invention thus makes a fundamental departure from the hitherto customary machine technology for laminating photovoltaic modules: Instead of forming the laminating device as a stationary press, which is loaded with layer stacks, and from which the laminated products are removed, optionally in batches and optionally with synchronous power strokes in one Multi-daylight press, the laminating device is now designed transportable and passed through the individual stations at least the laminating section of the manufacturing plant.

This means an advantageous renouncement of the complex and sometimes maintenance-intensive hydraulic system for opening and closing the hitherto conventional presses. Furthermore, there is no need for conveyor belts, which previously had to pass through the laminating device designed as a press in order to transport the layer stacks into the working chamber of the press and to be able to remove the laminated stacks of laminations laminated thereto in a first working cycle and optionally to a second working cycle to transport. Such conveyor belts are subject to high wear in the prior art, since they are subjected to the process heat at each working cycle of the press, which is typically in a temperature range of 140 to 160 ° C.

Other problems associated with a circulating conveyor belt in a conventional press-formed laminator, such as the need for correction mechanisms against increasing lateral offset of the conveyor belt (the belt run) or the need for cleaning due to adhesives that may have leaked out of the stack of sheets, are now covered by the present invention Invention eliminated.

In addition, in the conventional, designed as a press lamination an approximately necessary change of the pressing element, which is usually designed as a flexible membrane, basically associated with downtime, since the press is not ready for operation during maintenance or troubleshooting. If, on the other hand, several laminating devices designed as cassettes according to the invention are present in the system according to the invention, individual cassettes can be removed from the production line for maintenance or for troubleshooting without this being associated with downtimes of the production line.

The invention according to which the laminating device embodied as a cassette is transported through at least the individual stages of the lamination process, typically evacuation for degassing and removing air leakage between the individual layers of the layer stack, heating the layer stack, and pressing the layer stack Finally, also avoids a problem of a conventional, consisting of a plurality of juxtaposed presses lamination device, which consists in interrupting the lamination process and transporting the stack of layers between the individual presses sometimes for shrinking of films or for delay of the products can come.

Moreover, the cassettes according to the invention offer the advantage, which is particularly great in line production with a plurality of stations, of being able to be used for further processing steps in stations arranged upstream and / or downstream of the laminating section, without the layer stack having to be removed from the cassette , Thus, for example, only the lower part of the cassette according to the invention can be used as a kind of tray in which the laminated layer stack is provided with a frame, or in which the layer stack is placed before lamination - optionally, the electrical interconnection of the solar cell layer already in the lower part The cassette is made without the solar cell layer would have to be moved after that to integrate them into the layer stack to be laminated.

In the case of the laminating device according to the invention, it is preferable to use as press element a flexible, gas-tight membrane which divides the working chamber into a pressure space located above the membrane and a product space located below the membrane. Thus, the laminating device according to the invention on the main advantages, which also has a membrane press: The membrane can be clinging elastic by a pressure difference between the pressure chamber and the product space to the stack of layers and apply the necessary for lamination Auflast. For this purpose, it is sufficient in most cases to evacuate the product space and to aerate the pressure chamber. In order to apply greater loads on the layer stack, the pressure chamber may optionally be additionally pressurized, for example by introducing compressed air.

Such a membrane can be clamped in a sealing frame, which is arranged between the lower part and the upper part of the cassette and the working chamber seals circumferentially outwards. The channels for evacuating and / or pressurizing the pressure chamber and / or the product space in the working chamber can in this case in the sealing frame be integrated so that neither the lower part nor the upper part of the cassette must be provided with appropriate holes. In the context of the present invention, however, it can also be provided to provide at least the lower part of the cassette with suction channels for evacuating the vacuum chamber. This is particularly advantageous if the membrane is not clamped in a sealing frame.

In the context of the present invention, if no sealing frame is provided, it is preferred that the membrane be led outwardly over a contact surface between the base and the top of the cassette and thus be tensioned from outside the cassette and secured outside the cassette , This can facilitate a membrane change. In particular, this also makes it possible that the membrane acts as a seal between the lower part and the upper part of the cassette.

In the context of the present invention, as an alternative to a membrane, the pressing element arranged within the working chamber can essentially be designed as a movable plate. For example, it can be provided that a movable heating plate is arranged within the working chamber, on which the layer stack rests and with which the stack of layers for laminating up against the inner surface of the upper part or an additional counter-pressure plate can be moved to the necessary load on the layer stack applied. However, other embodiments are conceivable, such as two mutually movable plates below and above the layer stack, which in turn may be formed as heating plates. A combination of a movable plate with a membrane is conceivable within the scope of the present invention.

In order to be able to evacuate the working chamber of the cassette according to the invention or optionally at least the product space of a membrane-equipped cassette, it can be provided in the context of the present invention to arrange means for evacuation on the cassette, in particular a vacuum pump or vacuum hoses connected to the cassette be entrained, or a coupling system for coupling the cassette to a vacuum device. The latter can be done, for example, before the actual laminating; Since the cassette is closed gas-tight, it can hold a vacuum over a certain conveying distance, without having to be continuously evacuated.

The gas-tightness of the cassette according to the invention can be produced particularly simply by providing a peripheral seal, in particular a sealing cord, between the lower part and the upper part of the cassette. Thus, the cassette can be constructed much more easily than a press, so that the provision of a plurality of cassettes is no more expensive than installing a conventional press for laminating the layer stacks or photovoltaic modules. At the same time, the advantages according to the invention result in maintenance and troubleshooting and in terms of reduced wear and operating costs.

In the case of the cassette according to the invention, the means for introducing a process heat necessary for laminating into the layer stack preferably comprise at least one heating plate arranged in the working chamber, which can be heated in particular inductively and / or by means of electrical resistance heating elements. An electrical contact for resistance heating elements can be made on the conveyor line by means of sliding contacts or cable tow easily. An inductive heating can be done without contact anyway.

However, the means for introducing the process heat can also be integrated in the lower part and / or the upper part of the cassette, so that the lower part and / or the upper part are heated themselves and are responsible for introducing the process heat into the layer stack. Such means may be an inductively heatable material which is incorporated in the lower part and / or the upper part of the cassette or consists of the lower part and / or the upper part of the cassette. Alternatively, electrical resistance heating elements or heat channels can also be provided in the lower part and / or in the upper part, which can be flowed through by liquid heat carriers.

For introducing the process heat necessary for laminating into the working chamber of the cassette according to the invention, it is also possible to provide an inductively heatable film within the working chamber. This has the advantage of a low heat capacity, so that heating and cooling can be done quickly and energy efficient; In particular, it is then possible to apply heat to the cassette for lamination and then to cool the layer stack in the same cassette, without having to spend disproportionately much energy. The cooling can be done for example by water flowing through corresponding heat channels in the cassette.

Finally, it may be preferable to form the means for introducing the process heat as heat radiation permeable components of the cassette, so that the layer stack by Heat radiation can be heated from the outside, wherein the heat radiation can be generated outside the cassette, for example by means of infrared radiators.

Of course, in the context of the present invention, all described means for introducing the process heat can be combined with one another.

In order to be able to use the cassettes in as many stations along a production line as possible, it is preferred if the lower part of the cassettes according to the invention is designed as a tray transportable along the conveying path for inserting the layer stack. For laminating the layer stack then only the upper part must be placed gas-tight on the lower part, so that the working chamber is closed. At least as long as the stack of layers has not yet been laminated, it offers advantages when it is placed in a tray and is no longer moved relative to its base in order to pass through individual stations of a line production.

The cassettes according to the invention can be provided with sensors for detecting at least one pressure and / or for detecting the temperature within the working chamber, so that the process control is facilitated, for example by the sensors contactlessly reporting the detected values to a central process control.

The means for introducing the process heat are preferably at least partially designed so that they can also be used as a cooling device. As a result, the cassette according to the invention can be used for the active cooling of freshly laminated layer stacks. This is necessary depending on the adhesive used and in any case shortens the cycle time of the lamination process.

As far as the working chamber of the cassette according to the invention is not only to be evacuated and ventilated, but it should also be possible, for example, to pressurize the pressure chamber of a subdivided working chamber with additional pressure, it is preferred if the cassette according to the invention means for pressurizing the working chamber and / or the pressure chamber are arranged. These can be designed, for example, as a pump or as entrained pressure hoses or couplings for a compressed air system and the like.

The plant according to the invention for producing photovoltaic modules preferably has a device for placing and / or removing the upper part on or from the lower part of the cassette. Thus, in particular, it is ensured that the lower part of the cassette can be used as a tray for a plurality of process steps and the layer stack does not have to be removed from the working chamber in order to move from one process step to another. Preferably, such a device is provided with a guide system for the upper part to make the placement and / or removal during a transport movement of the lower part. For this example, slotted guides or handling machines come into consideration.

An automatic and automated placement and / or removal of the upper part can also offer advantages when the layer stack or the photovoltaic module is to be removed from a cassette in order to insert it into another cassette. This can be useful, for example, to remove the freshly laminated layer stack after the actual lamination process from a hot cassette and insert it into a cold cassette, where it is cooled down to room temperature.

The present in the system according to the invention conveyor system for transporting the cassettes can be provided with branches in the conveyor line and with parallel paths, so that process steps that require more time can be made in a section of the conveyor system, due to a parallel path twice or n times is available. As a result, the entire production line does not have to be adapted to the speed of the slowest process step.

In this case, the conveying path can have a plurality of sections for different process steps whose length is proportional to the time required for the respective process step to be carried out in this section. By grinding or detours, possibly also by a kind of paternoster system, the cycle times for the individual process steps can be coordinated with one another without having to vary the conveying speed of the individual cassettes.

Particularly preferred in a system according to the invention in the conveyor section a Ausschleusstelle provided for maintenance or troubleshooting. Cassettes that need to be cleaned, serviced or repaired can be removed from the process without hindering any other process. For example, a membrane can be changed or tightened without causing any downtime of the system.

Preferably, a vacuum section is provided in the conveying path of a system according to the invention, in which a vacuum station for evacuating the working chambers of the cassettes is arranged. Conveniently, the cassette passes this Vacuum section immediately after the upper part has been placed on the lower part; because even a slight evacuation of the working chamber generates Zuhaltekräfte that make further securing of the upper part of the lower part of the cassette superfluous. If appropriate, it is also possible to evacuate this already to the extent necessary for the lamination process. Then the cassette does not require any further suction measures when passing through the laminating section, as long as the gas-tightness of the working chamber is sufficient to maintain the desired vacuum in the product space over the entire laminating section.

In the laminating section of the conveyor line of the system according to the invention, a heat station is preferably arranged, in which the required process heat is introduced into the working chamber of the cassette. Depending on the configuration of the cassettes used, this heat station can be provided with heat radiators and / or with an induction heating and / or with electrical contacts for electrical resistance heating elements.

The conveyor line of the system according to the invention can have one or more transfer stations for transferring the layer stacks or the photovoltaic modules from a first cassette to another cassette. For energetic reasons, it may be useful, for example, to transfer a freshly laminated layer stack, which still has the temperature required for lamination, from a heated cassette into a cold cassette in order to cool it or to be actively cooled.

The conveyor line of the system according to the invention may finally have an insertion station and a removal station and buffer zones for temporary storage of cassettes.

An exemplary embodiment of a laminating device designed according to the invention as a cassette and an exemplary embodiment of a system according to the invention are described and explained in more detail below with reference to the accompanying drawings. Show it:

1 a schematic representation of a production line for photovoltaic modules according to the prior art;

2 an embodiment of an inventively designed lamination, in the open state;

3 the embodiment 2 in closed condition;

4 a schematic representation of the embodiment of 2 in a system designed according to the invention;

5 a schematic representation of the embodiment of 2 in a differently configured system according to the invention,

6 a schematic representation of an inventively designed production line for photovoltaic modules.

1 shows a production line for photovoltaic modules according to the prior art, ie a system for the production of photovoltaic modules, as it is known. At the beginning of the process, a glass layer is applied over a glass washing machine 1 and a solar cell layer on a conveyor system 2 put on and over a first foil cutter 3 an adhesive layer, usually consisting of an EVA film, placed between the glass layer and the solar cell layer. A stringer unit 4 provides the electrical interconnection of the individual solar cells in the solar cell layer, after which a second EVA film and a backsheet on a second film cutter 5 be hung up. The stations run through here form a laying section 6 within one of the support system 2 formed conveyor line 7 ,

The in the laying section 6 the conveyor line 7 Layers stack is then in a laminating 8th the conveyor line 7 transported further, where two parallel arranged, as pressing 9 configured laminating devices are arranged. In these, the layer stacks are laminated by means of pressure and heat. The presses 9 are stationary and have a press bottom and a press top, which can be hydraulically separated and collapsed to open a working chamber located therein and close. By means of circulating conveyor belts, the layer stacks of the conveyor system 2 taken off, by the presses 9 transported through and downstream to the conveyor system again 2 to hand over. In the presses 9 For example, a plurality of layer stacks are laminated at the same time, for which reason the successively arriving layer stacks are collected upstream and batchwise into the press 9 must be inserted. Conversely, the finished laminated layer stacks are downstream of the presses 9 isolated in order to be able to process them successively.

After passing through a laminate testing station 10 and a border trim station 11 become the laminated layer stacks in a framing station 12 provided with a circumferentially surrounding the edges of the frame and a corresponding edge-sealing seal. By means of a device 13 to the Installation of junction boxes, the photovoltaic modules are completed, then by means of an LED flasher 14 checked and in a packaging device 15 packed for delivery.

In the 2 and 3 is an embodiment of an invention as a cassette 16 configured laminating in each case a schematic lateral section shown, wherein 2 the cassette 16 in the open state shows while 3 the cassette 16 in closed state represents.

The cassette 16 consists of a lower part 17 and a top 18 , which can be placed on each other and a working chamber 19 form between themselves. A membrane 20 that have a contact surface 21 between the lower part 17 and the top 18 through the working chamber 19 passed through on all sides to the outside, divides the working chamber 19 in a product room 22 and a pressure room 23 , The product room 22 is located below the membrane 20 and is here on the one hand from the lower part 17 as a cassette 16 formed laminating and on the other hand of the membrane 20 limited. The pressure room 23 is located above the membrane 20 and will from this as well as from the top 18 the cassette 16 locked in.

Inside the work chamber 19 is in the product room 22 a lower heating plate 24 arranged while in the pressure room 23 , above the membrane 20 an upper heating plate 25 located. The bottom heating plate 24 is from the bottom part 17 the cassette 16 spaced apart, leaving a stack of layers 26 to be laminated on the lower heating plate 24 can be placed and there in about the same height with the membrane 20 lies when the cassette 16 closed is ( 3 ). This is advantageous because the membrane 20 then hardly has to deform during the lamination process to get to the stack of layers 26 snugly and apply the necessary for the lamination process surcharge on this.

The lower part 17 the cassette 16 is with a suction channel 27 provided while the top 18 the cassette 16 a ventilation duct 28 having. About the suction channel 27 can with closed cassette 16 the product room 22 be evacuated, so that in 3 shown situation in which the membrane 20 to the stack of layers 26 snugly. About the ventilation duct 28 can the pressure room 23 be vented and optionally provided with compressed air to the pressure difference between the product space 22 and the pressure room 23 according to the desired load, with which the membrane 20 on the layer stack 26 to act. Meanwhile, the layer stack becomes 26 by means of the lower heating plate 24 and by means of the upper heating plate 25 subjected to the process heat necessary for laminating, so that the adhesive material layer softens, and depending on the material, either crosslinked or cured.

Preferably, the pressure chamber 23 not vented to ambient pressure, but it is left a slight negative pressure in the pressure chamber, so that the working chamber 19 overall lower pressure than the environment. This leads to locking forces between the upper part 18 and the lower part 17 the cassette 16 so that the working chamber 19 remains closed, without the cassette 16 to lock, so the shell 18 and the lower part 17 to connect with each other. Of course, it is within the scope of the present invention, however, also possible to provide connecting elements, the lower part 17 and the top 18 the cassette 16 set together and can be locked accordingly. Because if a surcharge on the layer stack 26 is to act, which is higher than the difference of typically one millibar and ambient pressure, the pressure chamber 23 be subjected to compressed air, causing the cassette 16 eager to open up.

The one on the contact surface 21 between the shell 18 and the lower part 17 the cassette 16 protruding membrane 20 as a side effect ensures the gas-tight sealing of the contact surface 21 and thus the working chamber 19 ,

The lower and upper heating plates used in the present embodiment 24 . 25 be by means of electrical resistance heating elements 29 heated, which are inductively charged with the necessary electrical power.

4 shows schematically the use of the cassette 16 as they are in the 2 and 3 is shown, in a conveyor line of an inventively designed system. In an insertion station 30 becomes the layer stack 26 in the lower part 17 the cassette 16 inserted. This is the bottom heating plate 24 slightly raised and edge with a cover 31 provided that should prevent the membrane 20 stretches too much during the lamination process at these locations and into the product space 22 pulled in, which could damage it.

After closing the cassette 16 this will be along the conveyor line 7 , more precisely in the laminating section 8th the conveyor line 7 first in a vacuum station 32 spent. There, first, the pressure chamber 23 the cassette 16 , between the membrane 20 and the top 18 , evacuated to a final vacuum (typically around 1 mbar) for pre-evacuation. As a result, during the Pre-evacuating the membrane 20 at the top 18 is held. Subsequently, the product room 22 that is between the membrane 20 and the lower part 17 located above the suction channel 27 evacuated (typically to 1 mbar plus differential pressure to the pressure chamber 23 ). This will make the layer stack 26 deprived of the leg air to avoid blistering in the product. To initiate the lamination process, the pressure chamber 23 over the ventilation channel 28 ventilated. As a result, the membrane nestles 20 to the layer stack 26 , as well as next to this to the lower heating plate 24 or the cover 31 at. Maintaining a slight negative pressure in the pressure chamber 23 causes the top 18 and the lower part 17 the cassette 16 Zuhaltekräften is exposed, an accidental opening of the cassette 16 prevent.

Further transport of the cassette 16 leads to a laminating station 33 , in which the actual lamination process takes place: through the evacuated product space 22 and the vented, or provided only with a slight negative pressure chamber 23 brings the membrane 20 due to the pressure difference between the product space 22 and the pressure room 23 a surcharge on the layer stack 26 on. At the same time, the lower and upper heating plates 24 . 25 heated to process temperature, whereby the process heat necessary for laminating in the layer stack 26 is introduced. The process heat activates the adhesive layer.

In a subsequent cooling station 34 becomes the layer stack 26 inside the cassette 16 cooled down again while the Adhäsivstoffschicht completely cures or the networking comes to a close. The cooling station 34 can with the same cassette 16 be passed through, the previously already the laminating and optionally also the laying section 6 has gone through. In a downstream subsequent removal station 35 becomes the cassette 16 opened again, leaving the finished laminated layer stack 26 can be got out of this.

Based 4 is easy to understand that the lower part 17 the cassette 16 can be used separately as a tray by first the individual layers, and then the layer stack and after laminating the semi-finished photovoltaic module along the conveyor line 7 Going through station for station is transported.

5 shows a variation of the plant part 4 , In which the individual stations are arranged not only horizontally one after the other in line, but can also be passed through one another horizontally in a kind of paternoster system.

In 6 is how in 1 , a production line for photovoltaic modules shown schematically, this production line with cassettes according to the invention 16 Is provided. The laminating section 8th So does not contain the usual in the art, as pressing 9 designed lamination, but it is the laminating 8th essentially a part of the conveyor system 2 , which, in the case shown, four cassettes 16a . 16b . 16c . 16d via an induction heating 36 transported by means of which the heat required for lamination in the product spaces 22 the cassettes 16a to 16d is introduced. At the upstream end of the laminating section 8th there is a device 37 for putting on the upper part 18 on the lower part 17 a cassette 16 while at the downstream end of the laminating section 8th a device 38 for removing the upper part 18 from the lower part 17 a cassette 16 is arranged. The device 37 for putting on the upper part 18 includes a vacuum pump connected to the closed cassette 16 can be connected to their working chamber 19 or product space 22 to evacuate. The device 38 for removing the upper part 18 the cassette 16 is reversed with a means for venting the working chamber 19 or the product space 22 the cassette 16 fitted.

Thus, in the in 6 schematically shown production line again at the beginning of the process, a glass layer over a glass washing machine 1 and a solar cell layer on a conveyor system 2 put on and over a first foil cutter 3 an adhesive layer is placed between the glass layer and the solar cell layer. As preferred in the present invention, this is done directly in a base 17a a cassette. This lower part 17a will be on the conveyor system 2 in the laying section 6 the conveyor line 7 then through the stringer unit 4 transported ( 17b ), where the individual solar cells in the solar cell layer are electrically connected. In the second foil cutter 5 is a second EVA film and a backsheet, directly in the bottom 17c the cassette, placed on the electrically interconnected solar cell layer.

Further transport into the laminating section 8th the conveyor line 2 leads the lower part 17 the cassette 16a then into the device 37 for putting on a top 18 on the lower part 17 , causing the cassette 16a is completed. Here then also their working chamber 19 or first their pressure chamber 23 to pre-evacuate and then their product space 22 evacuated for the lamination process.

The transport of the cassette 16b . 16c . 16d via the induction heating 36 causes in the lamination section 8th laminating the one in the cassette 16b . 16c . 16d arranged layer stack. The length of this section may vary depending on the requirements of the Duration of the lamination process can be varied. To the end of the laminating section 8th the cassettes arrive 16 into the device 38 for removing the upper part 18 from the lower part 17d where first the working chamber 19 or their product space 22 is vented to then the shell 18 from the lower part 17d to be able to lose weight.

The laminating section 8th the conveyor line 7 can therefore be run according to the invention, without the transport in the cassettes 16 or their subdivisions 17 arranged to stop, or even have to form batches to be laminated to the layer stack, after the laminating 8th to be separated again. Instead, the lower part runs 17 every cassette 16 continuously through the laying section 6 and the laminating section 8th the conveyor line through.

Following the laminating section 8th the finished laminated layers remain in the lower part 17e and thus pass through the laminate testing station 10 and the edge trim station 11 , Only for the other elements of the production line, the framing station 12 , the device 13 for setting outlets, the LED flasher 14 and the packaging device 15 the laminated layers are then removed from the base 17e the cassette 16 removed. At this time, the crosslinking or curing of the adhesive films and the cooling of the layer stack is completed, so that there is no longer any risk of film shrinkage or slippage of the individual components relative to one another.

In the 1 to 6 As well as in the above description, only one example of a specific embodiment of the laminating apparatus according to the invention and a production line according to the invention for the production of photovoltaic modules is shown and described, whereby the invention defined in the claims, far beyond the specific embodiments, invention is not limited. Thus, for example, it is possible to laminate the layer stacks in the cassettes without membrane, or to introduce the process heat required for lamination with a plurality of hot plates or only with a hot plate or without hot plates in the cassette, or to use the hot plates as pressing elements by being movable be configured, or instead of a linear conveyor system to realize a turntable concept and the like.

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Cited patent literature

• DE 102009020172 A1 [0009]
• US 6367530 [0009]
• EP 2457728 A1 [0009]
• EP 1997614 A2 [0014]

Claims (30)

Laminating device for laminating at least one layer stack ( 26 ) with at least one glass layer and at least one adhesive substance layer by means of pressure and heat, comprising a lower part ( 17 ) and a top ( 18 ), which with the lower part ( 17 ) is gas-tight connectable or can be placed on this to an openable and closable gastight working chamber ( 19 ) for the layer stack ( 26 ), essentially within the working chamber ( 19 ) arranged pressing element ( 20 ) for applying a load for laminating necessary on the layer stack ( 26 ) as well as funds ( 24 . 25 ) for introducing a process heat necessary for laminating into the layer stack ( 26 ), characterized in that the laminating device consists essentially of a cassette ( 16 ), which at least the lower part ( 17 ), the top ( 18 ) and the pressing element ( 20 ) and the funds ( 24 . 25 ) for introducing the process heat and along a conveyor line ( 7 ) is transportable for several process steps at different locations in the conveyor line ( 7 ) to be used. Laminating device according to claim 1, characterized in that the pressing element is a flexible, gas-tight membrane ( 20 ), which is the working chamber ( 19 ) in one above the membrane ( 20 ) pressure space ( 23 ) and a product space located below the membrane ( 22 ) Splits. Laminating device according to claim 2, characterized in that the lower part ( 17 ) of the cassette ( 16 ) with suction channels ( 27 ) for evacuating the product space ( 22 ) is provided. The laminating apparatus according to any one of claims 2 or 3, characterized in that the membrane ( 20 ) in one between the lower part ( 17 ) and the upper part ( 18 ) of the cassette ( 16 ) arranged sealing frame is clamped. Laminating device according to claim 2, characterized in that the membrane ( 20 ) on all sides via a contact surface ( 21 ) between the lower part ( 17 ) and the upper part ( 18 ) of the cassette ( 16 ) is guided outwards and in particular as a seal between the lower part ( 17 ) and the upper part ( 18 ) acts. Laminating device according to claim 1, characterized in that the pressing element substantially as within the working chamber ( 19 ) movable plate is formed. Laminating device according to at least one of claims 1 to 6, characterized in that on the cassette ( 16 ) Means for evacuating the working chamber ( 19 ) and / or the product space ( 22 ) are arranged. The apparatus of claim 7, characterized in that the means (for evacuating the working chamber 19 ) and / or the product space ( 22 ) comprise a vacuum pump. Laminating device according to at least one of claims 1 to 8, characterized in that between the lower part ( 17 ) and the upper part ( 18 ) of the cassette ( 16 ) A circumferential seal, in particular a sealing cord is provided. Laminating device according to at least one of claims 1 to 9, characterized in that the means for introducing a process heat necessary for lamination in the layer stack ( 26 ) at least one in the working chamber ( 19 ) arranged heating plate ( 24 . 25 ), in particular inductively and / or by means of electrical resistance heating elements ( 29 ) is heated. Laminiervorrichtung according to claims 6 and 10, characterized in that the forming the pressing element movable plate as a heating plate ( 24 ) is trained. Laminating device according to at least one of claims 1 to 11, characterized in that the means for introducing a process heat necessary for the lamination in the layer stack ( 26 ) in the lower part ( 17 ) and / or the top ( 18 ) of the cassette ( 16 ) are integrated, in particular as inductively heatable material, as electrical resistance heating or as with liquid heat transferable through flow channels. Laminating device according to at least one of claims 1 to 12, characterized in that the means for introducing a process heat necessary for laminating in the layer stack comprise at least one inductively heatable film. Laminating device according to at least one of claims 1 to 13, characterized in that the means for introducing a process heat necessary for the lamination in the layer stack ( 26 ) substantially of heat radiation permeable components of the cassette ( 16 ) consist. Laminating device according to at least one of claims 1 to 14, characterized in that the lower part ( 17 ) of the cassette ( 16 ) than along the conveyor line ( 7 ) transportable tray for loading the layer stack ( 26 ) is trained. Laminating device according to at least one of claims 1 to 15, characterized that the cassette ( 16 ) with sensors for detecting at least one pressure and / or for detecting the temperature within the working chamber ( 19 ) is provided. Laminating device according to at least one of claims 1 to 16, characterized in that the means for introducing the process heat can be used as a cooling device. Laminating device according to at least one of claims 1 to 17, characterized in that on the cassette ( 16 ) Means for pressurizing the working chamber ( 19 ) and / or the pressure chamber ( 23 ) are arranged. Plant for producing photovoltaic modules in several process steps along a conveyor line ( 7 ) comprising a laminating section ( 8th ) for laminating at least one layer stack ( 26 ) with a solar cell layer, at least one glass layer and at least one adhesive layer under pressure and heat, characterized in that the system comprises a plurality of cassettes ( 16 ) according to at least one of claims 1 to 18, and a conveyor system ( 2 ) for transporting the cassettes ( 16 ) at least through the lamination section ( 8th ). Plant according to claim 19, characterized in that the plant comprises a device for placing ( 37 ) and / or losing weight ( 38 ) of the upper part ( 18 ) on or from the lower part ( 17 ) of the cassette ( 16 ). Plant according to claim 20, characterized in that the device for placing ( 37 ) and / or losing weight ( 38 ) of the upper part ( 18 ) on or from the lower part ( 17 ) of the cassette ( 16 ) with a guide system for the upper part ( 18 ) is provided for placing and / or removing during a transport movement of the lower part ( 17 ). Installation according to at least one of claims 19 to 21, characterized in that the conveyor system ( 2 ) with branches in the conveyor line ( 7 ) and provided with parallel paths Plant according to claim 22, characterized in that the conveyor line ( 7 ) several sections ( 6 . 8th ) for different process steps whose length is proportional to the time required for the respective process step to be carried out in this section. Installation according to at least one of claims 19 to 23, characterized in that in the conveyor line ( 7 ) a Ausschleusstelle is provided for maintenance or for troubleshooting. Plant according to at least one of claims 19 to 24, characterized in that in the conveyor line ( 7 ) a vacuum section with a vacuum station ( 32 ) to evacuate the cassettes ( 16 ) is provided. Plant according to at least one of claims 19 to 25, characterized in that in the laminating section ( 8th ) of the conveyor line ( 7 ) is provided with a heat station with heat radiators and / or an induction heating and / or electrical contacts for electrical resistance heating elements. Installation according to at least one of claims 19 to 26, characterized in that the conveyor line ( 7 ) at least one transfer station for transferring the layer stacks ( 26 ) from a first cassette ( 16 ) in another cassette. Installation according to at least one of claims 19 to 27, characterized in that the conveyor line ( 7 ) an insertion station ( 30 ) and a removal station ( 35 ) having. Installation according to at least one of claims 19 to 28, characterized in that the conveyor line ( 7 ) Buffer zones for temporary storage of cassettes ( 16 ) having. Using a cassette ( 16 ) according to at least one of claims 1 to 18 as a laminating device for laminating photovoltaic modules under pressure and heat.

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