Sept 2017 Fast, Safe , clean the Easy Lamination of Glass-Glass CONFIDENTIAL Page 1
Agenda Robert-Bürkle GmbH Motivation Dual-Glass Modules - Process Problems Dual-Glass Process investigation and development Vacuum-Flat-Press Laminator Conclusion Sept 2017 Fast, Safe , clean the Easy Lamination of Glass-Glass CONFIDENTIAL Page 2
Agenda Robert-Bürkle GmbH Motivation Dual-Glass Modules - Process Problems Dual-Glass Process investigation and development Vacuum-Flat-Press Laminator Conclusion Sept 2017 Fast, Safe , clean the Easy Lamination of Glass-Glass CONFIDENTIAL Page 3
Robert Bürkle GmbH Sept 2017 Fast, Safe , clean the Easy Lamination of Glass-Glass CONFIDENTIAL Page 4
Agenda Robert-Bürkle GmbH Motivation Dual-Glass Modules - Process Problems Dual-Glass Process investigation and development Vacuum-Flat-Press Laminator Conclusion Sept 2017 Fast, Safe , clean the Easy Lamination of Glass-Glass CONFIDENTIAL Page 5
Standard Module Problems (Glass-Backsheet) • UV Degradation causing the Yellowing • Delamination due to moistening and UV exposure • Moistening diffusion through the Back sheet (Big issue in Area with high humidity) • high thermal extension coefficient of Back sheet is responsible for delamination and Micro Cracks • PID issue or so called “Snail trails” Critical Regions for Standard Module design • High Temperature and humidity regions • Coastal regions • Deserts regions • Heavy snow and icy region Sept 2017 Fast, Safe , clean the Easy Lamination of Glass-Glass CONFIDENTIAL Page 6
Dual-Glass Modules Benefits and Motivation • Potential of longer lifetime and thus better ROI • Better mechanical stability • Better reliability • Potential of frameless modules • BIPV applications • Comparable weight with glass-back sheet modules, if thin glass is used • Bifacial cell concepts for high efficiency modules Glas Inter Edge Junction Inspection Stringer Layup Lamination washing connection Box trimming + Sorting Sept 2017 Fast, Safe , clean the Easy Lamination of Glass-Glass CONFIDENTIAL Page 7
Dual Glass Modules Future ITRPV predicts, increase in market share of double glass PV Source: ITRPV Sept 2017 Fast, Safe , clean the Easy Lamination of Glass-Glass CONFIDENTIAL Page 8
High Efficiency Bifacial Cell Concepts Bifacial Module – GL2GL PERC p-type Bifacial possible PERT n-type Bifacial possible HIT n-type Bifacial possible Picture from Intersolar 06/2013 Munich Almost all high efficieny cell concepts have a capability for Bifacial cell design. Which can increase the power in the module up to 25% depending on the Albedo. According IRTPV by 2025 percentage of bifacial cells will increase to 20% Sept 2017 Fast, Safe , clean the Easy Lamination of Glass-Glass CONFIDENTIAL Page 9
Reliability Tests for Dual-Glass Modules The Module reliability is affected by harsh environments with high temperature, high humidity or high UV conditions Thermal Cycling Test Humidity-Freeze Test Damp Heat Test -40 ° C to +85 ° C +85 ° C, 85% RH (Relative Humidity) +85°C to -40°C, 85% RH (Relative 200 & 400 Thermal cycles 1000 & 2000 Hours Humidity) 20 & 50 Cycles Zero water vapor ingress through the glass 35% to 43% less degradation as Almost Zero water vapor absorption 33% to 38% less degradation as compared compared to conventional back to conventional solar modules with back 30% to 58% less degradation as sheet solar modules sheet compared to conventional back sheet No occurrence of delamination solar modules Source: Trina Solar Sept 2017 Fast, Safe , clean the Easy Lamination of Glass-Glass CONFIDENTIAL Page 10
Mechanical Load Test To determine the ability of the module to withstand wind, snow, or ice loads Mechanical load is applied on both side of the modules and maintained for 1 hour Mechanical load increased from 2400Pa to 6700Pa Before After - No micro-cracks found on GG - Less degradation in GG Module module Source: Trina Solar Sept 2017 Fast, Safe , clean the Easy Lamination of Glass-Glass CONFIDENTIAL Page 11
Agenda Robert-Bürkle GmbH Motivation Dual-Glass Modules - Process Problems Dual-Glass Process investigation and development Vacuum-Flat-Press Laminator Conclusion Sept 2017 Fast, Safe , clean the Easy Lamination of Glass-Glass CONFIDENTIAL Page 12
Challenges in Glass-Glass Lamination Process Bubbles in the module corner or between the modules – which can lead to delamination Cell Breakage in Glass – Glass Module String movements in the Module Long Cycle times and low yield Sept 2017 Fast, Safe , clean the Easy Lamination of Glass-Glass CONFIDENTIAL Page 13
Agenda Robert-Bürkle GmbH Motivation Dual-Glass Modules - Process Problems Dual-Glass Process investigation and development Vacuum-Flat-Press Laminator Conclusion Sept 2017 Fast, Safe , clean the Easy Lamination of Glass-Glass CONFIDENTIAL Page 14
Pin System – cause Cell Breakage Sept 2017 Fast, Safe , clean the Easy Lamination of Glass-Glass CONFIDENTIAL Page 15
Bürkle Pin System Sept 2017 Fast, Safe , clean the Easy Lamination of Glass-Glass CONFIDENTIAL Page 16
Membrane Press via Flat Press – Step 2 Membrane press Flat press Top plate Membrane Bottom Plate Bottom Plate one side heating & double side cooling heating & cooling Step - 2 Final Lamination Step - 2 Final Lamination Cooling Press Pad Sept 2017 Fast, Safe , clean the Easy Lamination of Glass-Glass CONFIDENTIAL Page 17
Importance of heating plate Step 2 cooling Step 1 Double side heating and cooling Homogeneous heating and Bürkle pin system Inhomogeneous heating One side heating and and other pin system cooling Sept 2017 Fast, Safe , clean the Easy Lamination of Glass-Glass CONFIDENTIAL Page 18
Membrane Press – Step 2 – distribution of Pressure Edge Pinch – frame needed EVA flow – membrane pressure Strings movements – membrane pressure Sept 2017 Fast, Safe , clean the Easy Lamination of Glass-Glass CONFIDENTIAL Page 19
Flat Press – Step 2 – distribution of Pressure No Edge Pinch - No frame needed EVA flow – flat plate pressure No Strings movements – flat plate pressure Sept 2017 Fast, Safe , clean the Easy Lamination of Glass-Glass CONFIDENTIAL Page 20
Agenda Robert-Bürkle GmbH Motivation Dual-Glass Modules - Process Problems Dual-Glass Process investigation and development Vacuum-Flat-Press Laminator Conclusion Sept 2017 Fast, Safe , clean the Easy Lamination of Glass-Glass CONFIDENTIAL Page 21
Bürkle Inline Lamination – 3 chamber application Bürkle Lamination Solution • Short process time • Full Automatic Inline process Step 1 - Pre- Step - 2 Final Cooling Lamination Lamination • Modular design possible • Low consumption • Small foot print • Perfect solution for mass production Sept 2017 Fast, Safe , clean the Easy Lamination of Glass-Glass CONFIDENTIAL Page 22
Ypsolar Process in VFF Sept 2017 Fast, Safe , clean the Easy Lamination of Glass-Glass CONFIDENTIAL Page 23
Results from Bürkle Recipe Good transparency No bubbles anywhere, no EVA overflow Sept 2017 Fast, Safe , clean the Easy Lamination of Glass-Glass CONFIDENTIAL Page 26
Agenda Robert-Bürkle GmbH Motivation Dual-Glass Modules - Process Problems Dual-Glass Process investigation and development Vacuum-Flat-Press Laminator Conclusion Sept 2017 Fast, Safe , clean the Easy Lamination of Glass-Glass CONFIDENTIAL Page 27
Conclusion for Dual-Glass Module Dual-Glass Module have high potential of longer Module lifetime, higher than average : Product Warranty over 30 years possible – 35% higher electrical output possible Slow module ageing due to climatic conditions Extremely high mechanical load capacity Dual-Glass Modules can be build without frame and with 2 mm Glass thickness, so the weight is similar to Glass-Backs sheet Modules. The Glass Modules provide highest safety in terms of transportation and installation, module cleaning, Fire and PID phenomenon Bifacial high efficiency cell concepts is getting higher attention in the market, this cell concepts highly requires Dual-Glass Modules. This new modules demanding new lamination requirements. Fully Automatic Inline Solution Contact Heating & Cooling from top & bottom No Frame usage during lamination Short Process Time – same as with Glass-Back sheet High Yield Sept 2017 Fast, Safe , clean the Easy Lamination of Glass-Glass CONFIDENTIAL Page 28
Thanks for your attention - Bürkle Lamination Systems 2141-1C VF(F) 2141-1C SL 2022-5/6/7 VFF 2022- 5/6/7 SL Glass-Glass Modules Glass-Glass Glass-Backsheet Modules with Crystalline Cells Thin Film Modules Sept 2017 Fast, Safe , clean the Easy Lamination of Glass-Glass CONFIDENTIAL Page 29
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