Design and Performance Validation of a Multi-Layer Laminator for Photovoltaic Modules

To address the demands of large-scale production in the photovoltaic industry for laminators with a small footprint, low energy consumption, and high encapsulation quality, this paper presents research on the structural design, simulation optimization, and performance validation of a multi-layer laminator for photovoltaic modules. Different from existing single-layer or double-layer structures, this paper proposes for the first time an eight-layer, three-stage overall scheme, develops modular lamination units, completes the design of core systems, and achieves multi-chamber coordination. Simulation validation was conducted on the temperature uniformity of the heating plates and the thermo-mechanical coupling under vacuum conditions. A prototype, model HCDL2743DSiT, was developed and subjected to a 30-day production trial. The results show that the equipment reaches a vacuum degree of 92 Pa within 100 s and drops to 38 Pa within 120 s; the temperature uniformity error of the heating plates is ±1.3 °C; the maximum positioning deviation of the transmission is ±2.8 mm. All core indicators meet the design requirements, and the module encapsulation pass rate reaches 99.9%. At the same production rate, the footprint is reduced by approximately 72% compared with that of a traditional double-layer laminator, achieving dual optimization of space utilization and energy consumption and providing technical equipment support for the high-efficiency encapsulation of photovoltaic modules.