MDF Thermal Film Laminating Machine Hot Press Dry Solar Module Laminating Machine

       It mainly operates based on the principle of hot-pressing technology. Multiple layers of materials such as laid-out photovoltaic cells, glass, backsheets, and encapsulation films are placed in the working chamber of the laminator.
      
      Through the application of a certain temperature and pressure by the upper and lower heating plates and maintaining it for a specific period of time, the encapsulation film melts and flows under the condition of being heated and pressurized, fully filling the gaps between each layer of materials. Then, after cooling and solidification, each layer of materials is tightly bonded together, and finally a complete and well-sealed photovoltaic module is formed.

1 Available in single layer, double layer, dual chamber, and triple chamber configurations to meet various customer needs.

2 Customized in-feed and out-feed tables are configured according to different lamination requirements and space needs.

         Beijing X-Solar Energy Co., Ltd. was found in 2020, and headquartered in Beijing. It's a science and technology innovative energy enterprises with the main business of future cell R&D, flexible photovoltaic modules, building photovoltaic module production, high-end equipment manufacturing, production line delivery, and AI-CITY wisdom energy management services.

          In July 2023, the company's first demonstration factory, Jiangsu X-Solar Green-building Technology Co., Ltd., was established in Jiangyin CNBM Jetion Industrial Park. Meanwhile, Jiangsu YuanTeng FengSheng Intelligent Manufacturing Technology Co., Ltd., a wholly-owned equipment company of the company, delivered the world's first "three-in-one" automatic production line for Jiangyin base. The production line can be compatible with the production of three categories: X-Solar Light shadow series (flexible PV modules), X-Solar Light rhyme series (building PVtile modules), X-Solar Light Curtain series (building PV wall modules), and customized products. X-Solar PV series products have the advantages of integrating architectural aesthetics, complying with design specifications and creating energy value, which have been widely recognized and praised by customers in domestic and overseas.

        In 2024, the company has added two regional centers in Shanghai and Guangzhou of China, and set up the Hong Kong X-Solar Future Energy Research Institute, and overseas sales companies in Australia, Italy, Germany, Saudi Arabia and Argentina. The company has launched a global layout to provide sustainable energy products and services to many countries, and has contributed to the "carbon neutrality and carbon peak".




 

Regarding issues related to operation and usage

Q: What preparations do I need to make when using a laminating machine for the first time?
Answer: Firstly, it is necessary to carefully read the user manual of the device, understand the operation methods of various functional buttons, parameter settings, etc; Next, check the appearance of the equipment for any damage and ensure that all components are securely connected; Then conduct power on, ventilation (if it is a pneumatic device) and other trial runs to check whether each system can start normally and reach the initial set state; Finally, use standard testing materials for trial production, familiarize yourself with the entire operation process, and observe the quality of the produced components.

Q: How to set the parameters of hot pressing on the laminating machine, such as temperature, pressure, and time?
Answer: The settings can be made through the device's built-in control system interface. Different models of devices may have different operating interfaces, but generally have dedicated parameter input areas. Enter the temperature value (usually accurate to specific degrees), pressure value (set according to the module size and process requirements), and hot pressing time (the time required from the beginning of the adhesive film melting to complete solidification) required for the corresponding photovoltaic module production process. After setting, the system will control the entire hot pressing process according to the set parameters.

Q: What are the precautions for placing and removing photovoltaic module materials during operation?
Answer: When placing materials, ensure that each layer of materials is laid flat, in the correct order, and that no debris is mixed in; The operation should be carried out as quickly as possible to minimize the exposure time of the working chamber to non vacuum and non set temperature environments. When removing components, wait for them to cool sufficiently to a safe temperature to avoid burns, and handle them carefully to prevent damage caused by collisions or other factors.

Regarding issues related to testing and quality control

Q: How to determine whether the quality of photovoltaic modules produced by the laminating machine is qualified?
Answer: It can be judged from multiple aspects such as appearance and electrical performance. Visually inspect for any bubbles, delamination, or overflow of adhesive film; In terms of electrical performance, professional testing equipment is used to check whether key parameters such as open circuit voltage, short circuit current, and fill factor of components meet standard requirements; The EL tester can also be used to detect whether there are hidden cracks and other defects inside the components, and these aspects can be comprehensively used to determine whether the component quality is qualified.

Q: If bubbles appear in the produced photovoltaic modules, what could be the problem with the laminating machine?
Answer: It may be due to a malfunction in the vacuum system, such as insufficient suction of the vacuum pump, air leakage in the vacuum pipeline, poor sealing of the vacuum valve, etc., which leads to insufficient vacuum in the working chamber, causing air to mix in when the adhesive film melts; It may also be due to inaccurate temperature control of the heating system, poor melting of the adhesive film, and failure to fill the gaps well, resulting in residual air and the formation of bubbles; It is also possible that there are problems with the material itself, such as poor quality of the adhesive film, moisture, and other factors that affect its normal use.

Regarding maintenance and upkeep issues

Q: What are the daily maintenance and upkeep tasks for the laminating machine?
Answer: It is necessary to clean the outside of the equipment in daily life, wipe off dust, oil stains, etc., and keep the equipment clean; Regularly clean the residual adhesive film, debris, etc. in the working chamber to prevent any impact on subsequent production; Check the operation status of key components such as heating plates, vacuum pumps, sensors, etc., and check for any abnormal sounds, overheating, or other phenomena; At the same time, pay attention to the operating parameters of the equipment to see if there are any deviations from the normal range, and promptly handle any abnormalities.

Q: How long does it take to perform comprehensive maintenance on the laminating machine?
Answer: It is generally recommended to perform comprehensive maintenance every certain period of operation (such as one month or one quarter, depending on the equipment manual and actual frequency of use). Comprehensive maintenance includes deep cleaning of each system, precision calibration of key components, replacement of worn parts, and re adding lubricant to lubrication parts to ensure that the equipment is always in good operating condition.

Q: How to maintain the heating plate of the laminating machine?
Answer: The heating plate should be regularly cleaned of residual adhesive film and other impurities on its surface to avoid affecting heating efficiency and heat uniformity. Suitable cleaning tools should be used during cleaning to avoid scratching the surface of the heating plate; Regularly check the heating performance of the heating plate to see if there is any local lack of heat or uneven temperature. If there is a problem, contact professional maintenance personnel for repair or calibration in a timely manner; In addition, when not in use for a long time, protective measures such as moisture-proof and dust-proof should be taken.

 Regarding troubleshooting issues

Q: What could be the possible reason for the heating plate not heating up after the laminating machine is started?
Answer: It may be a problem with the power connection, such as a broken power cord, loose plug, etc., causing the power to not be turned on; It may also be due to damage to the heating elements inside the heating system, such as the burning of resistance wires; It is also possible that there is an error in the temperature setting of the control system, or that electrical components such as relays controlling the heating plate have malfunctioned, resulting in the inability to supply power to the heating plate and raise its temperature.

Q: How to troubleshoot if the vacuum system has a slow pumping speed?
Answer: First, check if the vacuum pump is running normally, and check if the motor is working and if there are any abnormal noises; Next, check if there are any blockages or leaks in the vacuum pipeline. You can inspect the sealing of the pipeline connections in sections and check if there are any foreign objects blocking the interior of the pipeline; Then check if the vacuum valve is fully open and if there are any issues such as valve core damage that affect its normal opening degree; Finally, check whether the pumping capacity of the vacuum pump has decreased, such as wear on the impeller of the vacuum pump, poor sealing of the pump body, etc. If there are any problems, repair or replace the corresponding components in a timely manner.

Question: What should be done if the pressure system displays unstable pressure?
Answer: First, check if the pressure sensor is working properly and if its accuracy is accurate. If the sensor malfunctions, it may cause abnormal display and needs to be replaced or calibrated; Then check whether the pressure regulating valve and other regulating components are flexible, whether they are blocked or damaged. If there are any problems, they should be cleaned, repaired or replaced; At the same time, it is necessary to check whether there is any leakage in the entire pressure system pipeline. If there is a leakage, it will cause unstable pressure. Sealing treatment can be carried out at the leakage point.

Regarding issues related to production efficiency

Q: How to improve the production efficiency of photovoltaic module laminating machines?
Answer: On the one hand, it can optimize the operation process, reduce time waste in material insertion, extraction, and equipment waiting, such as arranging loading and unloading personnel reasonably to achieve seamless connection; On the other hand, by precise tuning of equipment parameters, the hot pressing time can be appropriately shortened while ensuring component quality; Regular maintenance and upkeep of the equipment can also be carried out to ensure that it is always in optimal operating condition, reducing downtime for repairs due to malfunctions and thus improving overall production efficiency.

Q: Is there a significant difference in production efficiency among different models of laminating machines?
Answer: There will be differences, mainly depending on factors such as the design capacity of the equipment, the performance of the heating and pressure systems, and the degree of automation. For example, large-scale, highly automated laminating machines with fast heating and pressing speeds can process more components at once or complete the hot pressing process faster, resulting in relatively higher production efficiency; However, the production efficiency of some small, manually operated laminating machines with average system performance may be lower.

Regarding safety issues

Q: What safety precautions should be taken when using a laminating machine?
Answer: It is necessary to ensure that the operators have received professional training, are familiar with the equipment operation process and emergency response methods; During equipment operation, it is strictly prohibited to insert hands or other body parts into the working chamber to prevent accidents such as burns and injuries; Regularly check whether the grounding of the equipment is good to prevent potential leakage hazards; In addition, for high-temperature and high-pressure parts such as heating systems and pressure systems, protective measures and warning signs should be taken to avoid accidental contact by unrelated personnel.

Q: What are the safety protection devices for the laminating machine?
Answer: It is usually equipped with a high temperature alarm device. When the temperature of the heating plate exceeds the set safe upper limit, an alarm will be issued and heating will automatically stop to avoid the danger of fire and other hazards; There is also a pressure overload protection device. Once the pressure exceeds the safe range, the pressure source will be immediately cut off to prevent equipment damage due to excessive pressure and ensure the safety of operators; In addition, some devices are also equipped with emergency stop buttons. In case of sudden emergency situations, pressing the button can quickly stop the operation of the device.

Regarding issues related to the scope of application

Q: Can laminating machines be used for the production of all types of photovoltaic modules?
Answer: Most common photovoltaic modules, such as crystalline silicon photovoltaic modules and thin film photovoltaic modules, can be produced using a laminating machine. However, for some photovoltaic modules with special structures and materials, it may be necessary to adjust some parameters and components of the laminating machine or replace specialized matching fixtures before production can be carried out. However, the basic principles and hot pressing processes are still similar.

Q: What aspects need to be adjusted when producing photovoltaic modules of different specifications on the same laminating machine?
Answer: It is necessary to adjust the parameters of the hot pressing, such as adjusting the pressure size reasonably according to the size of the components, to avoid damage to the components caused by excessive pressure or weak bonding caused by insufficient pressure; Adjust the temperature distribution settings of the heating plate to ensure that all parts of the large-sized components are evenly heated; It is also necessary to adjust the hot pressing time according to the thickness of the components to ensure that the adhesive film can fully melt and solidify, so that the materials of each layer can bond well.

Regarding the issue of equipment selection

Q: What factors should be considered when choosing a photovoltaic module laminating machine?
Answer: We need to consider production scale and capacity requirements. If the output is large, we should choose large, high-speed, and highly automated equipment; Attention should also be paid to the precision control capability of the equipment, as parameters such as temperature, pressure, and time with high precision control can better ensure component quality; The stability and reliability of the equipment are also important, and it is advisable to choose brands with good reputation and low failure rates; In addition, the maintenance cost of the equipment, the convenience of operation, and after-sales service also need to be taken into consideration.

Q: What are the advantages and disadvantages of imported laminating machines compared to domestically produced ones?
Answer: Imported laminating machines may have advantages in some aspects, such as advanced process technology in some high-end imported equipment, excellent performance in precision control and stability, and high brand awareness, suitable for production scenarios with extremely high requirements for component quality; But the disadvantage is that the price is usually higher, the procurement cost is high, and the supply cycle of parts during after-sales maintenance may be longer, resulting in higher maintenance costs. Domestic laminating machines have developed rapidly in recent years, with high cost-effectiveness and the ability to meet most conventional production needs. They also have fast after-sales service response times and relatively low maintenance costs. However, in some high-end technology fields, there may still be a certain gap compared to imported products.