Multi-layer laminate structure and manufacturing method

1. A method of constructing a multi-layer laminate structure, comprising the steps of:

a. providing a lamination frame, wherein the frame includes a first frame surface, a second frame surface and an external side frame surface interconnecting the first and second surfaces defining a frame thickness, further wherein the frame includes an internal side frame surface that projects towards the second frame surface from the first frame surface at least through a portion of the frame thickness defining a first frame pocket and a first frame pocket side wall profile, further wherein the lamination frame provides at least one of holding, locating, and dimensional control during the manufacturing of the multi-layer laminate structure;

b. providing a first layer including a first layer top surface portion, first layer bottom surface portion, and a first layer side surface portion interconnected between the top and bottom portions, wherein the first layer has a first layer length and first layer width adapted to fit within the first frame pocket;

c. providing a second layer including a second layer top surface portion, second layer bottom surface portion, and a second layer side surface portion interconnected between the top and bottom portions, wherein the second layer includes an energy activated flowable polymer and further wherein the second layer has a second layer length, a second layer width, and a second layer thickness such that it can at least partially flow into and fill at least a portion of a first gap between the internal side frame surface and the first layer side surface portion;

d. introducing the first layer to the first pocket;

e. placing the second layer bottom surface portion at least partially in communication with the first layer top surface portion creating a multi-layer stack;

f. applying an energy source to the lamination frame, the multi-layer stack, or both, causing the energy activated flowable polymer to bond to the first layer and at least partially flow into the first gap between the first layer side surface portion and the internal side frame surface creating a bead with a bead width and a bead depth, the bead depth defined by a depth of the internal side frame surface;

g. allowing the energy activated flowable polymer to at least partially solidify, forming the multi-layer laminate structure, wherein the lamination frame is constructed such that it is capable of being removed after the energy activated flowable polymer has at least partially solidified; and

h. separating the multi-layer laminate structure from the lamination frame.

2. The method according to claim 1 , including the steps of:

providing a third layer including a third layer top surface portion, third layer bottom surface portion, and a third layer side surface portion interposed between the top and bottom portions; and

placing the third layer in at least partial communication with the second layer top surface portion or with the second layer bottom surface portion;

wherein these steps occur before step f of claim 1 .

3. The method according to claim 2 , wherein the third layer has a third layer length and third layer width less than that of the first pocket.

4. The method according to claim 2 , including causing the energy activated flowable polymer to bond to the third layer and at least partially flow into a third gap between the third layer side surface portion and the internal side frame surface creating the bead that is coextensive with that of step g of claim 1 .

5. The method according to claim 4 , wherein the third layer has a third layer length and third layer width greater than that of the first pocket.

6. The method according to claim 1 , wherein the first frame pocket side wall profile tapers inward by at least a 1.5° angle over at least a portion of the first frame pocket side wall as it progresses towards the second frame surface.

7. The method according to claim 1 , wherein a first pocket length, a first pocket width, or both of the first frame pocket is no greater than 10.0 mm larger than the first layer length, the first layer width, or both.

8. The method according to claim 1 , wherein the second layer length, the second layer width, or both is no greater than 10.0 mm larger than that of the first layer.

9. The method according to claim 1 , including the step of:

providing a second frame pocket including a second frame pocket side wall profile.

10. The method according to claim 9 , wherein the second frame pocket includes at least one insertable frame section.

11. The method according to claim 1 , wherein the first layer comprises a glass plate.

12. The method according to claim 2 , wherein the third layer comprises a photovoltaic cell assembly.

13. The method according to claim 1 , wherein the internal side frame surface that projects towards the second frame surface from the first frame surface does so through the entire frame thickness.

14. The method according to claim 1 , including the steps of:

providing a plurality of additional layers forming the multi-layer stack and placing the plurality of additional layers in at least partial communication with an adjacent layer, wherein these steps occur before step g of claim 1 .

15. The method according to claim 1 , including the step of:

providing at least one additional frame pocket including a frame pocket side wall profile.

16. The method according to claim 1 , including the steps of:

providing a vacuum source and placing the lamination frame along with the multi-layer stack under a vacuum.

17. The method according to claim 1 , wherein the multilayer stack includes at least a glass layer, a photovoltaic cell assembly layer, or a back sheet layer.

18. The method according to claim 1 , wherein the second layer has a second layer length, a second layer width, and a second layer thickness such that it can flow into and fill the first gap between the internal side frame surface and the first layer side surface portion.

19. The method according to claim 1 wherein the frame is integral in a structure with a plurality of identical frames and multiple first and second layers and optional third layers are provided such that multi-layer laminate structures are produced simultaneously.