DE102009019687B4 - Lamination apparatus and method for laminating and stacking component stacks - Google Patents

Abstract

Lamination device for laminating and framing stacks of components (100), the lamination device (1) comprising at least one evacuable pressing chamber (10) comprising an upper (11) and a lower (12) chamber wall for receiving one or more stacks of components (100), with between the upper and lower chamber walls (11, 12) are provided with a sealing frame (30) running around the edge of the chamber, which seals the pressing chamber (10) airtight, characterized in that at least one chamber wall (11) has a vertically movable section (11a, 11a '), which can fix the at least one component stack (100) in the chamber (10) by moving towards it, and with the sealing frame (30) a volume (40) for receiving injection molding material around the at least one component stack (100) delimits.

Description

The present invention relates to a lamination device for laminating and frame of component stacks, in particular a lamination device for laminating and frame of photovoltaic modules according to the preamble of claim 1. Furthermore, the invention relates to a corresponding method for laminating and frame of component stacks according to the preamble of patent claim ,

State of the art

Lamination devices, also called membrane presses, are used to compress from preferably plate-shaped components existing component stack by pressure under heat and / or under vacuum. Examples of finished components are in particular photovoltaic modules, but also other composite components such as laminated glass and composite components.

Such lamination devices generally comprise one or more press chambers, into which the component stacks are introduced, for example, by means of a conveyor belt passing through in the lower part of the chamber. The chamber comprises at least one heating device, for example an electric heating plate or a heat exchange device, and means such as a flexible and elastic, mostly made of silicone Anpressmembran for pressing the stack of components to the heater. The compression chamber can be pressurized with pressurized gas (eg, air) or simply vented or evacuated. The heating device, which is provided above and / or below the component stack, serves to supply the heat to the component stacks in the chamber which are required for lamination (for example for the melting of the inserted films).

The described lamination device produces compressed component stacks which, however, do not yet have all the capabilities desired by the end use. In particular, the component stacks still lack a support structure in which the laminated component stack must be installed. The most common example of such a support structure is a frame surrounding the laminated stack which protects the edges of the stack and permits installation and fixation of the stack of components (eg, photovoltaic modules on / in a roof). In the prior art are both aluminum frames that are prefabricated and then connected to the component stacks, as well as plastic frame known, the latter so far in a separate process and in a separate form, for example by Reinforced Reaction Injection Molding (RRIM) to The laminated stack of components are molded around. In these methods, it is disadvantageous that an additional method in an additional device is necessary for the production of the frame, which on the one hand increases production times and costs and on the other hand requires more space. Depending on the market price, the aluminum frame will incur even higher material costs and assembly costs. In addition, when using aluminum frames, the marginal area of the modules must be trimmed to eliminate the overhangs created during lamination.

Generic lamination devices are, for example, from DE 103 40 856 A1 , of the JP H08-072094 A , of the US 4,806,191 A and the WO 2009/018827 A1 known.

Presentation of the invention

It is thus an object of the present invention to develop a lamination apparatus for laminating and stacking component stacks that overcomes the above drawbacks and allows easier and more productive production of ready-to-use laminates. This object is achieved by a lamination device having the features of claim 1 and a method having the features of claim 9. Advantageous developments of the invention are defined in the respective subclaims.

The laminating device according to the invention for laminating and frame of component stacks comprises at least one evacuated pressing chamber comprising an upper and a lower chamber wall for accommodating one or more component stacks, wherein between the upper and lower chamber wall a sealing frame circulating around the edge of the chamber is provided which surrounds the pressing chamber in the closes airtight in its closed state. At least one chamber wall in this case comprises a vertically movable section which can fix the at least one component stack in the chamber by closing in on it and delimits a volume for receiving injection-molding material around the at least one component stack with the sealing frame and the respective chamber walls. The movable section is movable from an initial position, in which the chamber wall section is aligned with the rest of the chamber wall, into the chamber in order to fix the at least one component stack. To fix the stack of components here means to bring the at least one chamber wall portion from one side of the component stack to concern, while the other side of the component stack rests against the other, stationary or likewise movable chamber wall, so that in the subsequent injection of the Injection molding material no displacement of the stack takes place and the injection molding material finds a defined mold space. Thus, for example, the upper chamber wall having a movable portion with which the component stack can be pressed against the lower stationary chamber wall and fixed in this way. To demarcate a volume here means that the chamber walls, ie the movable portion of a chamber wall and the stationary or likewise movable portion of the other chamber wall, together with the peripheral sealing frame form a mold for the framing of the at least one component stack, from which the material is not in others Parts of the compression chamber can escape. The abovementioned suitability for fixing the component stack as well as for delimiting the volume is to be understood as referring to the closed press chamber.

The inventive design of the lamination, it is possible to produce in a machine and in a lamination with the continuous process provided with frame laminated component stack, which thus as finished products directly for installation or, in solar cell modules, for final assembly with the connection box To be available. This not only brings time and cost advantages by saving a separate Framing device and a Beschneidungsstation with it, but it can thus be created an even tighter process control that predetermine and coordinate all steps of a chamber, and thus can also adapt to specific requirements. Also, the lamination heat used can be used additively.

Preferably injection channels or lines are provided for injection molding material in the sealing frame of the device according to the invention. In this way, the material can be introduced directly into the delimited volume.

Furthermore, separate injection channels or lines with or without a mixing device are preferably provided in each case for components of a two-component injection molding material.

According to a preferred embodiment, the upper and the lower chamber wall each comprise at least one vertically movable section, wherein the sections can fix the at least one component stack by approaching each other at a predeterminable height in the chamber. The fixation at a predeterminable height allows the formation of application-specific shaped framing around the stack of components, as the shape of the demarcated volume changes as a function of the height of the fixation.

In a particularly advantageous embodiment, the device according to the invention further comprises a flexible release membrane provided above the component stack, serving as a release sheet, and a flexible pressure membrane provided below the component stack. If the chamber wall sections are moved and the mold volume for framing is delimited, the release membrane and the pressure membrane lay or stretch over the surfaces delimiting the volume and thus prevent a possible penetration of the subsequently injected injection molding material into the gap between the movable chamber wall section and the stationary remnant of the chamber wall. Furthermore, release and contact membranes contribute to easier removal from the mold due to their adhesion-reducing surface properties.

Preferably, at least one spacer element running essentially parallel to the chamber walls is provided within the sealing frame, which divides the pressing chamber partially or completely into subregions. These subregions may correspond to individual component stacks, so that the framing can take place for all individual component stacks in the press chamber. The spacers thus not only serve the spacing and structural support of the press chamber walls during lamination, but also delimit the mold volumes of adjacent component stacks from one another.

In a preferred embodiment, in this case movable cylinder pins are provided in a chamber wall, which are movable in the demarcated volume to form mounting holes in the injection molding material introduced there. In this way, the lamination device according to the invention can be used to produce a ready-to-install or ready-to-mount frame, and no further processing stations are required or less assembly means are required.

According to a further aspect, the invention also relates to a method for laminating and stacking components of components, comprising the following steps: First, at least one stack of components is introduced into a compression chamber having an upper and lower chamber wall and between the upper and lower chamber wall , surrounding the edge of the chamber encircling sealing frame, which closes the press chamber airtight; the pressing chamber is then closed pressure-tight and evacuated and the at least one stack of components is pressed; Subsequently, a portion of at least one of the chamber walls for fixing the at least one component stack in the chamber is moved vertically, wherein the at least one chamber wall portion thereby together with the sealing frame a volume around the delimits at least one component stack around; in the next step, an injection molding material is injected into the volume delimited around the at least one component stack; and then cured the injection molding material, wherein a framing is generated around the at least one compressed component stack.

With the method according to the invention, it is thus possible to produce laminated component stacks provided with frames in a single coherent process, which thus are available as finished products directly for installation or for final assembly with the connection box. This not only brings time and cost advantages by saving a separate framing process and a trimming step with the associated facilities or stations, but it can thus be created an even tighter process control that predetermine and coordinate all steps in a chamber, and thereby can also adapt to specific requirements. The lamination heat used during lamination can also advantageously be used for the injection molding step (frame formation), ie, additively.

In this case, at least one section of the upper and lower chamber walls are preferably moved vertically toward one another in order to fix the at least one component stack at a predeterminable height in the chamber. As a result, application-specific shaped framing can be formed around the stack of components as the shape of the demarcated volume varies as a function of the height of the fixture.

According to a further advantageous embodiment, fastening holes are introduced into the injection-molded framing in a further, but integrated, step. This can be achieved, for example, by the above-described cylindrical pins, which are arranged extendable in a chamber wall and which are extended before the final solidification and pressed into the injection-molded framing to produce the mounting holes. The formed at the end of the process, laminated and framed component stack are thus ready to install or assemble.

After the step of solidification, the at least one chamber wall section is preferably returned to its original position, thereby demoulding the at least one framed component stack. By moving back of the chamber wall section demolding is still performed in the chamber component stacks, which means that in the same chamber now also further (post-) treatment steps can be performed on the laminated and framed component stacks.

Preferably, the injection molding material is a polyurethane-based plastic. This material is characterized by its low thermal expansion, but above all by its good adhesive properties both on glass and on the other material components contained in the component stacks, for example EVA, PVS, PET, etc.

Brief description of the drawings

1 shows schematically a sectional view of a laminating device according to the invention for laminating and frame of component stacks, wherein five temporally successive stages of the inventive method are shown.

2 shows a perspective view of a viewed from below upper chamber wall, according to an embodiment of the laminating device according to the invention.

Ways to carry out the invention

In 1 Figure 3 is a schematic sectional view of a lamination apparatus during various steps of the lamination and framing process according to the invention. The device comprises a pressing chamber 10 with an upper and a lower chamber wall 11 . 12 , Both chamber walls each comprise a movable chamber wall section 11a . 12a , the upper section 11a using a heater 13 is heated. In the chamber 10 is also one on the lower chamber wall 12 overlying pressure membrane 20 and one on the upper chamber wall 11 arranged, serving as a release sheet release membrane 22 intended. To the chamber 10 encircling is a sealing frame between the upper and lower chamber wall 30 arranged, which seals the chamber in the closed state to the sides. In the sealing frame 30 are injection channels 32 provided, through which a plastic, preferably PUR, can be injected. The connections or other feed lines for the plastic and, alternatively, for the possibly required adhesion promoter (primer) are not shown for the sake of clarity. Furthermore, ventilation holes, not shown, are formed through the sealing frame, through which the chamber can be evacuated or ventilated. In 1 are finally provided in the upper chamber wall cylinder pins 18 (only one is shown) recognizable for the formation of mounting holes 102 in the frame 101 be used.

In the first step shown ( 1a ) becomes a component stack 100 , z. B. a from the still unconnected components carrier glass, semiconductor layers and cover films existing solar cell module in the chamber 10 introduced and on the Anpressmembran 20 positioned. The above the Anpressmembran 20 lying chamber part is then in the second step ( 1b ) evacuated, resulting in a bulge of the Anpressmembran 20 which leads the component stack 100 in the chamber thus raises. The component stack 100 gets up against the upper chamber wall 11 pushed through the heater 13 heated to a crosslinking temperature of about 150 ° C. Due to the heat and the contact pressure of the Anpressmembran 20 become the components in the stack of components 100 pressed together. The release membrane 22 , which consists for example of silicone, thereby preventing adhesion of the component stack 100 at the upper chamber wall 11 ,

After pressing, the pressing chamber 10 ventilated and the laminated component stack 100 ' is lowered again. Then, the upper and lower chamber wall portions 11a . 12a towards the center of the chamber, causing the laminated stack of components 100 ' between insert and fix. Through the chamber wall sections 11a . 12a and the insides of the sealing frame 30 thus becomes a mold volume 40 around the laminated component stack 100 ' formed around, the shape of a surrounding the component stack framing 101 having. The flexible and stretchable membranes 20 . 22 stretch over the chamber wall sections 11a . 12a and seal the between the stationary chamber wall parts 11b . 12b and the movable chamber wall sections 11a . 12a resulting column 14 from.

Through the injection channels 32 in the sealing frame 30 Now, for example, a PUR-based plastic, which may be, for example, a mixed with reinforcing materials RRIM plastic, in the mold volume 40 on and around the component stack 100 ' splashed around ( 1c ). After the mold volume 40 was completely filled, the curing process of the plastic begins. As long as the plastic is still soft, the cylinder pins 18 actuated and from the upper chamber wall 11 ( 11b ) extended, causing in the framing 101 of the component stack 100 ' at appropriate positions mounting holes 102 be generated. After the plastic has fully cured, the chamber wall sections become 11a . 12a returned to its original position ( 1d ), so now with a framing 101 provided, laminated component stack 100 ' is removed from the mold.

In 2 a further embodiment of the device according to the invention is shown. The figure shows a perspective view from below of the upper chamber wall 11 the device. At the upper chamber wall 11 is a sealing frame 30 firmly attached by a spacer 31 , in the present example cross-strut-like in the circumferential sealing frame 30 inserted and connected to it, in subregions 35 is divided. Every sub area 35 corresponds to the upper chamber wall 11 a movable chamber wall section 11a ' which is shown once in its retracted home position in the wall and once in its extended position. Also recognizable are also in the spacer element 31 provided injection channels 32 , In this embodiment, only the upper chamber wall 11 with movable chamber wall sections 11a ' equipped so that the height h _{D of} the sealing frame 30 (perpendicular to the main plane of the chamber wall) of the extension height h _{w of} the chamber wall portion 11a ' equivalent. For injection molding of the framing is thus one in a sub-area 35 located component stack from the upper chamber wall portion 11a ' pressed down to the lower chamber wall before the plastic passes through the channels 32 is admitted.

LIST OF REFERENCE NUMBERS

1

Laminationsvorrichtung

10

baling chamber

11

upper chamber wall

11a, 11a '

vertically movable chamber wall section

11b

stationary chamber wall part

12

lower chamber wall

12a

vertically movable chamber wall section

12b

stationary chamber wall part

13

heater

14

column

20

Anpressmembran

22

release membrane

30

sealing frame

31

spacer

32

Injection ducts

35

Subareas of the baling chamber

40

volume delimited around the stack of parts

100, 100 '

components stack

101

Framing

102

mounting holes

h _d

Height of the sealing frame

h _w

extension height

Claims (12)

Lamination device for laminating and mounting component stacks ( 100 ), the lamination device ( 1 ) at least one an upper ( 11 ) and a lower ( 12 ) Chamber wall comprehensive evacuatable pressing chamber ( 10 ) for receiving one or more component stacks ( 100 ), wherein between the upper and lower chamber wall ( 11 . 12 ) one around the edge of the chamber circumferential sealing frame ( 30 ) is provided, which the pressing chamber ( 10 ) hermetically sealed, characterized in that at least one chamber wall ( 11 ) a vertically movable section ( 11a . 11a ' ) comprising the at least one component stack ( 100 ) by driving into it in the chamber ( 10 ) and with the sealing frame ( 30 ) a volume ( 40 ) for receiving injection molding material around the at least one component stack ( 100 ) around. Lamination device according to claim 1, wherein in the sealing frame ( 30 ) Injection channels or lines ( 32 ) are provided for injection molding material. Lamination device according to claim 2, wherein separate injection channels or lines are provided in each case for all required components of a two-component injection molding material. Lamination device according to claim 1, 2 or 3, wherein the upper and lower chamber walls ( 11 . 12 ) each at least one vertically movable section ( 11a . 12a ), wherein the portions of the at least one component stack ( 100 ) can be fixed in the chamber by approaching each other at a predeterminable height. Lamination device according to one of the preceding claims, wherein the lamination device further comprises one above the component stack (s) ( 100 ), serving as a release sheet flexible release membrane ( 22 ) and one below the component stack (s) ( 100 ) provided flexible Anpressmembran ( 20 ). Lamination device according to one of the preceding claims, wherein within the sealing frame ( 30 ) at least one substantially parallel to the chamber walls ( 11 . 12 ) extending spacer element ( 31 ) is provided that the pressing chamber ( 10 ) partially or completely into subregions ( 35 ). Lamination device according to one of the preceding claims, wherein in a chamber wall ( 11 . 11b ) movable cylindrical pins ( 18 ) are included in the demarcated volume ( 40 ) are movable in order in the injection molding material there introduced mounting holes ( 102 ) train. Lamination device according to one of the preceding claims, wherein the sealing frame ( 30 ) on the upper or lower chamber wall ( 11 . 12 ) is firmly attached. Method for laminating and frame of stacks ( 100 ) of components, comprising the following steps: introducing at least one component stack ( 100 ) in a compression chamber ( 10 ), which have an upper and a lower chamber wall ( 11 . 12 ) and provided between the upper and lower chamber wall, surrounding the edge of the chamber sealing frame ( 30 ) comprising the pressing chamber ( 10 ) hermetically seals, pressure-tight closing and evacuation of the pressing chamber ( 10 ) and pressing the at least one component stack ( 100 ), vertical movement of a section ( 11a . 12a ) at least one of the chamber walls ( 11 . 12 ) for fixing the at least one component stack ( 100 ) in the chamber, wherein the at least one chamber wall section ( 11a . 12a ) together with the sealing frame ( 30 ) a volume ( 40 ) around the at least one component stack ( 100 ) around, injecting an injection molding material into the at least one component stack ( 100 ) delimited volumes ( 40 ), and solidification of the injection molding material, wherein a framing ( 101 ) around the at least one compressed component stack ( 100 ) is produced. Method according to claim 9, wherein at least one section ( 11a . 12a ) each of the upper ( 11 ) and lower ( 12 ) Chamber wall is moved vertically to each other to the at least one component stack ( 100 ) at a predeterminable height in the chamber ( 10 ) to fix. Method according to one of claims 9 or 10, wherein in a further step mounting holes ( 102 ) into the injection-molded framing ( 101 ) are introduced. Method according to one of claims 9, 10 or 11, wherein after the step of solidification the at least one chamber wall portion ( 11a . 12a ) is returned to its original position and thereby the at least one framed ( 101 ) provided component stack ( 100 ) is removed from the mold.

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