SOLARAWARDS2011 SHORTLISTED
Saint Gobain Solar SolarBond® InFrame
SolarBond® InFrame is an intelligent, innovative and instant solution for solar module manufacturing. An advanced framing concept for automated PV assembly lines, it is a revolutionary material developed by Saint-Gobain Solar. It combines the best attributes of liquid silicone sealants and frame tapes to create a pumpable material with the immediate adhesion advantage of tape solutions. This technology provides a fast; clean application for a durable seal that ensures a high-quality solar module, all while minimizing the costs associated with waste and production inefficiencies.
Product Challenge SolarBond® InFrame helps
manufacturer’s meets growing demand for solar modules while minimizing waste and related costs.
Problem Solved SolarBond® InFrame is applied warm in a continuous motion, ensuring both accuracy and high bonding strength immediately after contact with the glass, backsheet and frame. This eliminates the setting time needed for silicone products to cure by offering the instant adhesion of frame tapes coupled with a highly automated application process, shortening production cycles, reducing product waste and minimizing the associated production costs.
Additionally, the precision application eliminates the cleaning labour and costs incurred by the runoff cause by silicone sealants. The foamed material fills the aluminium channel in the frame completely, even in the corners, eliminating the risk of water collecting in the frame as experienced with tape solutions.
What results is a strong, long-term, weather-resistant bond for a durable final product. Used with Saint-Gobain Solar’s patented single-piece frame, it also reduces the number of corner keys required for framing the module, using just one instead of four as required for both, tapes and silicones, further reducing module costs.
Noteworthy SolarBond® InFrame is the only framing solution of its kind on the market today. It is the first of its kind to combine the pumpable application of liquid silicone with the instant adhesion of tapes in such a unique automated application.
Product in Detail SolarBond® InFrame is a new generation framing material that brings increased performance while reducing the overall production costs for PV module manufacturers. It is heated, foamed and extruded directly into the frame channel using an automated system (robot or fixed nozzle under moving frames). Frame and module assembly should be completed within two minutes of sealant application. Once assembled, modules can be handled immediately.
The foamed material is non-toxic, environmentally friendly and does not require special ventilation to meet industry safety standards. The material does not contain any substance subject to declaration in the International Material Data System list. No special labelling is required to comply with EC Guidelines. Foaming saves costs in two ways. First, the reduction in density reduces material usage and lowers sealant cost per module. Foaming is achieved using conventional foaming equipment designed for reactive materials.
Additionally, the risk of overflowing the channel after the laminate is inserted into the frame is minimized as the foamed material will not be displaced (unlike non- foamed wet sealant materials). No overflow means no need for post processing cleaning, lower labour cost and no production bottlenecks. SolarBond® InFrame is processed like a hot melt adhesive providing for excellent wetting of different surfaces and high initial adhesion.
Designed with optimum open time (1-2 minutes), the material has very short time to set once the laminate is inserted (under 15 seconds), thus enabling modules to be handled immediately after framing is
completed. Chemical crosslinking then further improves adhesion and internal strength providing for excellent long-term performance, even after exposure to severe environmental conditions.
Innovation
Incorporating SolarBond® InFrame into module manufacturing line presents several long-term advantages:
Minimizes labour and waste
Conventional liquid silicone solutions can leak out of the frame joint area when the module is inserted, requiring extensive cleaning. SolarBond® InFrame is foamed during the application process, allowing the material to compress internally without displacing onto the module. With no mess, manufacturers can forgo the costly labour of cleaning the module and disposing of the excess sealant, reducing overall costs and material waste.
Allows high-speed production, ideal for advanced lines
Developed for the factory of the future, SolarBond® InFrame allows an automated process for framing solar modules. Cycle times less than 35 seconds are now achievable.
In addition, instant adhesion allows modules to be handled immediately and transported with no movement in the frame, ensuring a high-quality product. Reduces costs by minimizing production inefficiencies caused by slower acting adhesives and reducing labour, SolarBond® InFrame presents significant cost savings, helping PV module manufacturers to produce high-quality products faster and at a lesser expense than with traditional framing solutions.
In addition, used with Saint-Gobain Solar’s patented single-piece frame, it also reduces the number of corner keys required for framing the module, using just one instead of four as required for both tapes and silicones, further reducing module costs.
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www.solar-pv-management.com Issue VII 2011
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