The invention relates to a production device for a layer arrangement with a light-reactive element, in particular a multilayer solar module, with the features in the preamble of the main claim.
Such a production device for a layer arrangement having at least one light-reactive element is known from the WO 2011/151 430 A2
respectively. DE 20 2010 005 555 U1
known. They have a laminator with a frame which has a stationary support for the layer arrangement to be built thereon. Furthermore, the manufacturing device has a buckling and relaxation device for a plate-shaped layer and a vacuum device on the support.
In the EP 0 755 080 A2
a similar manufacturing device for solar modules is addressed with a suction table, wherein a flexible EVA film is deformed and laminated by the negative pressure.
The DE 10 2007 038 240 A1
shows a further manufacturing device for solar modules with a casting table and a separate linear robot and a plurality of separate heating devices. The linear robot has adjustable suction cups for feeding and bending a glass plate.
It is an object of the present invention to further improve the previously known production technology.
The invention solves this problem with the features in the main claim.
The claimed manufacturing technique, i. the manufacturing facility and the manufacturing process, have procedural advantages. The process time and the utilization of the manufacturing facility as well as the manufacturing quality can be improved. In addition, there are economic benefits.
The use of a mobile workpiece carrier makes it possible to spatially and temporally separate the layer formation process and the usually longer curing process of the layer arrangement. The in the manufacturing facility on the workpiece carrier in parts or completely constructed layer arrangement can be thermally treated and completed in a downstream curing device. To a manufacturing device more curing devices can be connected. The manufacturing device and the curing device (s) may be part of a manufacturing plant.
The claimed conveying device together with the movement device and the stationary carrier mount allow a transport of empty and loaded workpiece carriers into and out of the production device and an exact positioning of the workpiece carrier in the process position on the laminator. As a result, the process and production quality can be secured and even increased despite mobility.
The mobile workpiece carrier can serve one or more integrated vacuum channels for sucking parts of the layer arrangement, in particular the one or more light-reactive elements and optionally a liquid or pasty compound applied thereto. In this way, a bubble-free and air-free encapsulation of the light-active elements can be achieved. The vacuum channels can be switched in a network with one or more, possibly separate vacuum circuits, which allows an optimal adaptation to the respective workpiece requirements. The vacuum can also be maintained during transport of the workpiece carrier and the layer assembly by means of a self-retaining closure. This ensures the position of the layer arrangement during transport and in the subsequent further processing, in particular the curing of the bonding compound (s).
The workpiece carrier can be multifunctional and can also be used for sucking and fixing a plate-shaped layer by means of a marginal seal. This is advantageous if a base module initially formed of several layers can be turned and then fixed again on the workpiece carrier for the further layer structure on the other module side.
The workpiece carrier can also have one or more exchangeable inserts with receiving means for electrical cross-connectors of the layer arrangement, in particular of a solar module. As a result, the workpiece carrier can be adapted in a simple and cost-effective manner to different types of layer arrangements, in particular of solar modules. The cross connectors can also be held on the inserts by suction pressure. The peripheral seal and the interchangeable inserts have an independent inventive significance and can also in a stationary workpiece carrier or a table-like support according to the WO 2011/151 430 A2
The mobile workpiece carrier can also have a releasable clamping device with which the layer arrangement can be fixed on the workpiece carrier, if necessary, in particular during transport and further processing. The Clamping device is self-holding and can be opened or released for the layer formation process on the production device by means of a local release device.
The invention further provides, for the buckling and relaxation device, a pressure roller which is controlled in the normal direction, in particular in height, to the uppermost layer of the layer arrangement and, if necessary, controlled in a controllable manner. By means of this, the infeed and the contact pressure can be adjusted and optimized as required. The adjusting device is equipped for control purposes with a corresponding sensor, which advantageously scans the workpiece carrier, in particular its surface facing the layer arrangement, as a reference object. In this way, on the one hand, any position inaccuracies of the mobile workpiece carrier can be compensated and, on the other hand, predetermined setpoint values for the thickness of the layer arrangement can be maintained. The controlled or controllable delivery device for the pressure roller also has independent inventive significance and can also in a buckling and relaxation device according to the prior art, in particular according to the WO 2011/151 430 A2
, be used advantageously.
The manufacturing device may further comprise a mobile and relative to the workpiece carrier and the layer arrangement movable heating device. This can serve for local heating of the layer arrangement, which on the one hand improves the efficiency and uniformity of a first thermal fixation of the bonding compound (s) and on the other hand minimizes the heat losses. The latter is particularly advantageous if the workpiece carrier to optimize the shape and dimensional accuracy of metal and has a corresponding thermal conductivity. In a particularly favorable embodiment, the heating device is designed as a radiation heater which is suspended above the layer arrangement and preferably coupled in terms of motion with the pressure roller. This embodiment of the heater also has independent inventive importance and can be successful even with a stationary workpiece carrier, eg according to WO 2011/151 430 A2
In the subclaims further advantageous embodiments of the invention are given.
The invention is illustrated by way of example and schematically in the drawings. In detail show:
1 and 2 : a production device in different phases of the layer formation process in a schematic side view,
3 and 4 a conveyor for a mobile workpiece carrier with a lifting device in different operating positions,
5 and 6 a detachable clamping device arranged on the workpiece carrier and entrained in different operating positions,
7 and 8th : a workpiece carrier with exchangeable inserts for transverse bands in various embodiments,
9 : an enlarged and broken representation of a detail X of 8th .
10 and 11 : a workpiece carrier with an applied layer arrangement and a peripheral seal in plan view and folded side view,
12 : a mobile workpiece carrier with integrated vacuum channels and a connection for a dockable vacuum supply,
13 : an enlarged view of a detail XIII of 12 and
14 and 15 : a layer arrangement in plan view and in longitudinal section.
The invention relates to a production device ( 2 ) and a production method for a multilayer layer arrangement ( 1 ). The invention further relates to a production plant ( 3 ), which is a manufacturing facility ( 2 ) and one or more further stations.
14 and 15 show in a schematic example a multi-layer arrangement ( 1 ), which is designed here as a solar module. It has several light-active elements ( 14 ) in the form of solar cells spaced at a mutual distance ( 20 ) and in a uniform matrix ( 19 ) are arranged. The solar cells ( 14 ) can communicate with each other to form one string ( 18 ) with lines ( 21 ) be electrically connected. The matrix ( 19 ) consists of several adjacent strings ( 18 ). The pipes ( 21 ) can at the ends in any suitable manner by electrical cross connectors ( 22 ) and interconnected.
15 shows an example of a layer structure in longitudinal section. The solar module ( 1 ) consists of five layers ( 13 . 14 . 15 . 16 . 17 ). A first outer layer ( 13 ) is formed by a plate-shaped and translucent support, for example a glass or plastic plate. On top of that is a layer ( 15 ) From a compound, such as a liquid or pasty silicone composition. In the Connection layer ( 15 ) are the solar cells ( 14 ) bubble-free embedded. On the solar cells ( 14 ) there is another connection layer ( 17 ), on the outside a cover layer ( 16 ) rests, which may be formed plate-like or foil-like and which consists for example of an opaque backing film made of plastic. The connecting layers or bonding compounds ( 15 . 17 ) may consist of the same material, in particular of a silicone material. They can be applied in liquid or pasty form, evenly distributed with expulsion of air bubbles and cured after formation of the layer structure shown under heat, whereby they develop an adhesive effect.
In a modification of the embodiment shown, the one or more light-reactive elements ( 14 ) consist of other light-absorbing elements or of light-emitting elements, such as LEDs. One or more tie layers ( 15 . 17 ) may be formed in other ways, for example as adhesive films or the like. Furthermore, the number, formation and order of the layers may vary.
1 shows a schematic side view of a production facility ( 2 ) for a layer arrangement ( 1 ). The manufacturing facility ( 2 ) has a laminator ( 4 ) for forming a layer arrangement ( 1 ) on a mobile workpiece carrier ( 6 ) on. For the transport of one or more workpiece carriers ( 6 ) is a conveyor ( 7 ) available.
Furthermore, the production device ( 2 ) a feeder ( 5 ) for one or more layers, in particular for the plate-like carrier ( 13 ) and possibly also for the one or more light-reactive elements ( 14 ) exhibit. Alternatively, a manual feed is possible.
The laminator ( 4 ) has a stationary frame ( 8th ) with a carrier mount ( 39 ) for the workpiece carrier ( 6 ) on. Furthermore, the laminator ( 4 ) a vaulting and relaxation device ( 9 ) for the in 1 shown plate-shaped layer ( 13 ) on. In addition, an application device ( 10 ) for a bonding compound ( 15 . 17 ) and a heating device ( 11 ) and a vacuum device ( 12 ) to be available.
The manufacturing facility ( 2 ) can from a housing ( 53 ), which one or more locks for the passage of the workpiece carrier ( 6 ) having. The manufacturing facility ( 2 ) may be part of a manufacturing plant having one or more other stations, eg a curing station, a trim and assembly station or the like.
The in 7 to 13 illustrated workpiece carrier ( 6 ) is plate-like and consists of a suitable material, preferably metal, in particular a light metal. The workpiece carrier ( 6 ) has a plate-like body ( 23 ) with an overhead contact surface ( 29 ), on which the layer arrangement ( 1 ) is constructed in the manner described below.
The body ( 23 ) has one or more integrated vacuum channels ( 24 ), which with several at the bearing surface ( 29 ) opening suction openings ( 25 ) are connected. The suction openings ( 25 ) are used to capture the applied light-active elements ( 14 ) and can be distributed and arranged accordingly. The one or more vacuum channels may form a conduit network having one or more vacuum circuits, which may be separately controllable. The vacuum channels ( 24 ) or the vacuum circuits are connected to one or more terminals ( 26 ) on the body ( 23 ), eg connected to a cabinet side wall, to which an external vacuum supply ( 42 ) can detachably dock with suitable coupling elements. The vacuum supply ( 42 ) is eg on the laminator ( 4 ), in particular on its frame ( 8th ).
The mobile workpiece carrier ( 6 ) may also contain a self-retaining closure ( 27 ), which ensures the maintenance of the vacuum with uncoupled vacuum supply, in particular during carrier transport. The closure ( 27 ) may be formed, for example, as a spring-loaded check valve, which when connecting the vacuum supply ( 42 ) and is opened by applying negative pressure. The closure ( 27 ) can be connected to a port ( 26 ) can be arranged. The latter can also be a seal for the said coupling element of the vacuum supply ( 42 ) exhibit.
As 10 and 11 can clarify the workpiece carrier ( 6 ) at the receiving surface ( 29 ) a seal ( 28 ), eg an elastomeric sealing cord, which is arranged, for example, on the edge and peripherally. It surrounds the suction area with the suction openings ( 25 ) and can be found in the 11 shown a lying and the suction area cross-plate-like layer ( 13 ), in particular the said carrier, suck in and hold.
The contact surface ( 29 ) may optionally groove-like depressions for receiving the lines ( 21 ) of the photoactive elements ( 14 ) exhibit.
As 7 to 9 clarify, the workpiece carrier ( 6 ) one or more exchangeable inserts ( 30 ), which are arranged at a suitable location, preferably on opposite narrow sides. The modular inserts ( 30 ) one or more receiving means ( 31 ), eg one or a plurality of grooves, for receiving in each case a cross connector ( 22 ) of the layer arrangement ( 1 ) exhibit. The receiving means ( 31 ) can be adapted to a particular cross connector arrangement, which, depending on the type of layer arrangement ( 1 ) can vary. In case of a type change, the insert or inserts ( 30 ) exchanged. If other electrical cable connections or connections are used, a correspondingly differently designed and on the workpiece carrier ( 6 ) arranged insert ( 30 ) to be used.
As in particular the detail of 9 shows a changeable use ( 30 ) an integrated vacuum channel ( 24 ) with a at the receiving means ( 31 ) or at the groove bottom opening suction port ( 25 ) exhibit. At the suction opening ( 25 ) or at the groove ( 31 ) can also be a seal ( 28 ) can be arranged. The one or more vacuum channels ( 24 ) can be suitably connected to the other vacuum channels ( 24 ) in the body ( 23 ). Alternatively, you can have your own connection for docking to an external vacuum supply ( 42 ) exhibit. In the variant of 7 are recording means ( 31 ) without vacuum channels ( 24 ) and suction openings ( 25 ). The above-mentioned vacuum device ( 12 ) is supplied by the external vacuum supply and by the mobile workpiece carrier ( 6 ) arranged vacuum channels ( 24 ) and suction openings ( 25 ) and connections ( 26 ) educated.
5 and 6 show a mobile workpiece carrier ( 6 ) equipped with a tensioning device ( 33 ) is equipped and this also carries during transport. The tensioning device ( 33 ) serves the layer arrangement ( 1 ) as needed on the workpiece carrier ( 6 ) to tension and fix. By means of a suitable and preferably on the laminator ( 4 ), in particular on its frame ( 8th ) arranged release device ( 43 ), the tensioning device ( 33 ) are opened and released.
The tensioning device ( 33 ) consists of eg a hold-down ( 34 ), which is bar-shaped and the layer arrangement ( 1 ) or the body ( 23 ) and in the clamping position from above on the layer arrangement ( 1 ), in particular on an overhead plate-shaped carrier layer ( 13 ) presses. The hold-down ( 34 ) is peripherally in a suitable manner, for example, height adjustable guided on upright pins and can by a clamping element ( 36 ), for example, a spring arranged on the respective pin, are acted upon. The tensioning device ( 33 ), an adjustment means ( 35 ), eg an adjusting screw, with which, if necessary, the height of the hold-down ( 34 ) relative to the workpiece carrier ( 6 ) and its bearing surface ( 29 ) can be adjusted and adjusted.
The release device ( 43 ) can be formed, for example, by lifting means, in particular lifting cylinders, which are connected to the holding device ( 34 ) and this to release the clamping engagement of the layer arrangement ( 1 ) take off.
The initially mentioned conveyor ( 7 ) is used to transport one or more workpiece carriers ( 6 ) in and out of the manufacturing facility ( 2 ), possibly with passage through the mentioned lock on the housing ( 53 ). The conveyor ( 7 ) is eg as a belt conveyor ( 37 ) educated. It can be a movement device ( 38 ), with which the workpiece carrier ( 6 ) between, for example, a raised transport position and a lowered process position on the laminator ( 4 ) can be moved. The movement device ( 38 ) can be designed, for example, as a controllable lifting device with lifting cylinders or the like.
The frame ( 8th ) according to 1 and 2 a stationary carrier mount ( 39 ) for the defined recording of the workpiece carrier ( 6 ) in the process position. The stationary support ( 39 ) has a defined receiving surface ( 40 ) and a positioning and fixing device ( 41 ) for the exact mounting of the workpiece carrier ( 6 ) in the process. The receiving surface ( 40 ) may be continuous or preferably interrupted. 1 and 2 show the process status. The lowered conveyor ( 7 ) is moved from the workpiece carrier ( 6 ) and in a suitable manner temporarily in the frame ( 8th ) housed.
The vaulting and relaxation device ( 9 ) of the manufacturing facility ( 2 ) is in 1 and 2 shown schematically. It has a pressure roller ( 44 ) with a means of transport ( 45 ), eg a carriage, along the workpiece carrier ( 6 ) can be moved in its process position. The means of transport ( 45 ) has a suitable controllable drive for this purpose. The pressure roller ( 44 ) may also have a controllable rotary drive, which is possibly matched with the carriage drive. In this case, the linear carriage movement can be synchronized with the rolling movement.
The pressure roller ( 44 ) can with an adjusting device ( 46 ), with which they in the normal direction to the receiving surface ( 29 ) of the workpiece carrier and to the layer arrangement constructed there ( 1 ) can be controlled and possibly also adjustable adjustable. With the adjusting device ( 46 ) can in particular the roller height relative to the workpiece carrier ( 6 ) and the receiving surface ( 29 ).
The adjusting device ( 46 ) has a sensor system ( 47 ), which for the controlled or controlled roller delivery the workpiece carrier ( 6 ) when Reference recorded and preferably scanned. The sensors ( 47 ) can be designed for this in any suitable manner, for example as the sensing roller shown on the surface of the workpiece carrier ( 6 ) in the area next to the actual support surface ( 29 ) for the layer arrangement ( 1 ) rests. The sensors ( 47 ) can alternatively work without contact.
The manufacturing facility ( 2 ), the above-mentioned mobile and relative to the workpiece carrier ( 6 ) and the layer arrangement ( 1 ) movable heating device ( 11 ) exhibit. This can movement with the driving movement of the pressure roller ( 44 ). You can have this for its own and preferably controllable means of transport. You can alternatively at the means of transport ( 45 ) of the pressure roller ( 44 ) or connected to this via a tow bar or the like. The heater ( 11 ) serves for local heating of the layer arrangement ( 1 ). It is suspended above the layer arrangement ( 1 ) and overlaps them. The heater ( 11 ) may be formed in a suitably suitable manner, for example as a layer arrangement ( 1 ) executed beam-like radiation heating, in particular as an infrared radiator.
The feeder mentioned at the beginning ( 5 ) can be designed as multiaxial movable, controllable handling device. Preferably, it is a multi-axis industrial robot ( 51 ), in particular as an articulated arm robot, and carries on the output member a gripping tool ( 52 ). In 1 is the robot ( 51 ) represented schematically and represented by a robot arm shown aborted.
As 1 and 2 clarify, the bulge and relaxation device for the positioning and support of the plate-like layer to be bent and relaxed ( 13 ) a height-adjustable holding device ( 48 ) at one layer edge and a positioning means ( 32 ), eg a stop, on the opposite layer edge. The height-adjustable holding device ( 48 ) and the positioning means ( 32 ) can be attached to the workpiece carrier ( 6 ) and / or on the frame ( 8th ) of the laminator ( 4 ) can be arranged. The vaulting and relaxation device ( 9 ) can also have a layer holder ( 49 ), eg a height-adjustable suction arrangement, on the stop-side layer edge. The height-adjustable holding device ( 48 ) can be designed in different ways, for example as a controlled extendible plunger or as a height-adjustable suction arrangement, which at the top or bottom of the plate-like layer ( 13 ) attacks.
In a preferred embodiment of the layer formation process, a workpiece carrier ( 6 ) and moved into the process or work position on the carrier mount ( 39 ) and positioned and fixed there. Subsequently, the light-reactive elements ( 14 ) individually, in the form of strings ( 18 ) or as a complete matrix ( 19 ) on the support surface ( 29 ) and held with suction pressure. The pad can be manually or by means of the feeder ( 5 ) happen automatically. The cross connectors ( 22 ) can already be installed or later mounted in the process flow and with the lines ( 20 ) get connected.
In the next step, the liquid or pasty compound ( 15 ) with the applicator ( 10 ) on the light-reactive elements ( 4 ) applied in a suitable distribution. Subsequently, the plate-like layer ( 13 ) manually or automatically by means of the feeder ( 5 ) and to the height-adjustable holding device ( 48 ) as well as the layer holder ( 49 ) to hand over. The layer holder ( 49 ) is lowered and places the associated layer end on the bonding compound ( 15 ) with simultaneous alignment on the positioning means ( 32 ). The plate-like layer ( 13 ) thereby receives a concave curvature, which is then relaxed, the layer ( 13 ) on the bonding compound ( 15 ) is expressed and rolled.
For relaxation, the pressure roller ( 44 ) according to 2 forward, where it is controlled or regulated delivered in height. The rolling engagement begins at the already deposited layer end, wherein the layer holder ( 49 ) is removed and the opposite initially extended holding device ( 48 ) is lowered according to the roll feed. In this controlled lowering and rolling movement of the plate-like layer ( 13 ) the compound mass ( 15 ) evenly distributed over the layer surface and also in the column ( 20 ), whereby in addition in possibly free spaces and in the connecting layer ( 15 ) gases, in particular air inclusions, are expelled. The vacuum device ( 12 ) is turned on in the relaxation and also sucks the gases located in the process area, in particular air pockets from. By pressing and rolling the plate-like layer ( 13 ) the light-active elements ( 14 ) bubble-free in the bonding compound ( 15 ) embedded. The bonding compound ( 15 ) may be translucent and especially transparent in this embodiment.
During the relaxation and the roll feed, the heating device ( 11 ) and the pressed layers ( 13 . 14 . 15 ) and the bonding compound ( 15 ) thermally solidify in a first step. In addition, at the one stop-side layer edge also the initially released tensioning device ( 33 ) through the Deactivation of the release device ( 43 ) are brought into clamping engagement and secure the layer composite.
With the layers ( 13 . 14 . 15 ), a base module is first constructed, which then with sufficient solidification of the layer composite manually or by the feeder ( 5 ) and with the plate-shaped layer ( 13 ) down on the support surface ( 29 ) and can be sucked in there. Subsequently, the application device ( 10 ) the further compound compound ( 17 ) on the layers ( 14 . 15 ) applied.
Then, in the next step, the top layer ( 16 ) applied. For this example, one of the pressure roller ( 44 ) associated layer feed ( 50 ), in particular Folienzufühung be provided, wherein the pressure roller ( 44 ) an integrated suction device for circumferentially holding the supplied from a winding supply cover layer or film ( 16 ) having. The cover layer ( 16 ) can also be applied in a rolling process. Alternatively, the cover layer ( 16 ) consist of a less biegeeastischen plate body and applied with the above-described buckling and relaxation process. The further connection layer ( 17 ) can also be used with the entrained heater ( 11 ) and thermally preconsolidated.
After completion of the layer arrangement ( 1 ) the tensioning devices arranged on both layer edges fall ( 33 ) and fix the layer arrangement ( 1 ) on the workpiece carrier ( 6 ). The conveyor ( 7 ) takes the released workpiece carrier ( 6 ) and transports it from the production facility ( 2 ) out. It can then be transported while maintaining the clamping engagement and possibly also the suction to a curing station in which the connecting layers ( 15 . 17 ) are suitably cured by light, radiation, heat or the like. In optionally subsequent processing steps trim work, a junction box assembly or the like. Other edits to the layer arrangement ( 1 ).
Variations of the embodiments shown and described are possible in various ways. The order of the construction steps in the formation of the Schichtanordung ( 1 ) may vary. Furthermore, structural modifications of the above-described machine and device components are possible. The edge seal ( 28 ), one or more exchangeable inserts ( 30 ), the adjusting device ( 46 ) for the pressure roller ( 44 ) and the movable and local heating device ( 11 ) could also be used in a manufacturing facility ( 2 ) are used with a stationary and designed as a table-shaped support workpiece carrier. The same applies to the clamping device ( 33 ). The other components of the manufacturing facility described above ( 2 ) may be the same in this modified embodiment.
Furthermore, the features of the above-described embodiments can be combined with each other in different ways and optionally also replaced.
LIST OF REFERENCE NUMBERS
- Layer arrangement, solar module
- Manufacturing facility, manufacturing station
- manufacturing plant
- Feeding device, handling device
- Workpiece carrier
- Curving and relaxation device
- vacuum equipment
- Layer, carrier, glass plate
- Layer, light-reactive element, solar element
- Layer, bonding compound, silicone layer
- Layer, cover layer, foil
- Layer, bonding layer
- Distance, gap
- Corpus, plate
- vacuum channel
- suction opening
- Connection of vacuum supply
- bearing surface
- Insert changeable
- Receiving means, groove
- Positioning means, stop
- tensioning device
- Stripper plate
- Adjustment means, screw
- Clamping device, spring
- belt conveyors
- lifting device
- support receptacle
- receiving surface
- Positioning and fixing device
- vacuum supply
- release device
- Mode of Transport
- setting device
- Sensors, feeler roller
- Holding device height adjustable
- Layer holder, sucker
- Layer feed, film feed
- industrial robots
- gripping tool
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
- WO 2011/151430 A2 [0002, 0012, 0014, 0015]
- DE 202010005555 U1 
- EP 0755080 A2 
- DE 102007038240 A1