Against the backdrop of the global energy transition and China’s dual-carbon strategy, the photovoltaic (PV) industry is entering a new stage of large-scale, intensive development, where efficiency improvement and cost control in module encapsulation have become the core of industrial competition. To address the drawbacks of traditional silicone plate laminators—frequent consumable replacement, high maintenance costs, and poor adaptability to dual-glass module encapsulation—this paper proposes a flat-plate laminator technical scheme. By replacing flexible silicone plates with rigid pressure plates and optimizing pressure transmission paths and sealing structures, we achieved efficient, low-cost lamination. We first compared the working principles of flat-plate and silicone plate laminators, completed the structural design of five core modules with an optimized rigid platen and annular silicone sealing system, developed a modular retrofitting scheme for existing equipment, and verified performance via engineering tests. Tests show that the retrofitted equipment achieves a module thickness deviation ≤ ±0.06 mm, a product yield of 99.88%, annual cost savings of USD 342,000 per unit, and a 0.61-year investment payback period. This work provides theoretical support and an engineering reference for technical innovation in PV module encapsulation equipment, with significant promotion and application value.
Jin et al. (Sun,) studied this question.