Tailored in three steps: Improved productivity and cycle times of the module lamination process

Bürkle entered the photovoltaic market in 2007, with a multi-opening lamination lines Ypsator, using the already existing process knowhow from the lamination sector (lamination of printed circuit boards, plastic cards and wooden moulded parts). Many of the laminators which were in use at that time, were mostly prototypes which have not been fully developed for the special needs of the PV industry.

For this reason the multi-opening lamination lines Ypsator with the new three-step procedure was developed. The lamination process was divided in order to increase the process flexibility and to reduce the cycle time. This functions as follows:

The modules are pre-laminated in the first step. This means that the humidity and the air pockets are removed from the sandwich in the vacuum and that a vacuum-tight compound is created. Then the process is interrupted and in a second step, the lamination is finished in a subsequent press. In a third step, the "cooling", the machine cools down the solar module from 150°C to hand-hot temperatures.

Especially the lamination of glass modules is very stress-reduced which diminishes, last but not least, also the breakage of glass due to the three-step process and the structure of the three laminating steps.

In order to keep the photovoltaic modules water-tight and thus functioning for 25 years, the machine has to laminate the used materials (for example safety glass, encapsulation foils and crystalline solar cells) to a "solar sandwich" and has to function very exactly. Regular temperature distributions onto the entire surface (~150°C) as well as reproducible and continuously documented processes make the difference of the laminator model.

Another plus factor: The machine can be designed for the conception of a complete line and the integration can be space-saving, especially for large production capacities. By its structure and the homogeneous temperature distribution that can be achieved through heating of the heating platens by means of thermal oil, the process times are essentially reduced. The yellow-grey "solar machine" is supplied in different sizes from three to ten openings. Based on the modular concept and the flexibility of stacks the laminator can be tailored to the planned fab capacity using the smallest footprint with the highest throughput per square meter in this industry.

Currently the photovoltaic market is in strong motion. Many module manufacturers prepare for the economic revival. Since the same is strongly cost-driven, compact line concepts on small production surfaces with shorter and shorter cycle times and very high production outputs with several 100 MWp per year are in demand. So our focus is on achieving the best Total Cost of Ownership. Based on the three step process the target is to minimise the yield losses caused by the lamination process below 1%.

With the Ypsator the lamination process was divided in order to increase the process flexibility and to reduce the cycle time

In the 90 years since its foundation, Bürkle has set new standards for lamination and coating technologies in a variety of industries. In 2007, the company responded to market demands for efficient and reliable high-performance systems by developing the Ypsator, a pioneering product in multi-opening lamination technology.  Since then, more than 60 single- and multi-opening lamination systems have been supplied to our customers.

Bürkle offers comprehensive, one-stop system solutions. We deliver full back end systems for the manufacture of thin film and crystalline modules. In addition, process components such as coating, handling, foil cutting and layup systems round off our product portfolio.

With  its  many  manufacturing  locations  in  Germany  and  China  and  a  tightly  knit  network  of service  and  distribution  partners,  Bürkle  is  a  globally  active  company  and  a  skilled  partner  that is always at your service, wherever you are. Every day, we conduct research in collaboration with customers and partners at our Innovation Center in Freudenstadt, Germany. The development of new innovative systems solutions allows us to maintain our role as a strong driving force in the market.

In 2010 Bürkle will hold steady the number of employees at 480 at the sites in Freudenstadt and Mastholte. The group currently employs 700 staff members worldwide. Bürkle has been rewarded with the "TOP 100" award this year again.

Visit us:

25th EU PVSEC, 06. - 09.09.2010, Valencia, Spain - hall L2/H2 booth no. D10

Solar Power International, 12. - 14.10.2010, San Francisco, USA - booth no. 443

www.buerkle-gmbh.de