Method for manufacturing a frame for a photovoltaic module and frame for a photovoltaic module

Abstract

The embodiment of the present application provides a kind of photovoltaic module frame manufacturing method and photovoltaic module frame, and the photovoltaic module frame manufacturing method includes: providing reinforcing layer;Glass fiber and reinforcing layer are added to the forming mold with resin;Glass fiber, reinforcing layer and resin are cured in forming mold;The pultrusion profile of extrusion forming is pulled out from the outlet of forming mold by traction device, wherein the pultrusion profile includes reinforcing layer and the resin and glass fiber of cladding reinforcing layer;Cut the pultrusion profile, to obtain photovoltaic module frame, wherein the mass fraction of reinforcing layer in photovoltaic module frame is 10%-50%.The photovoltaic module frame manufacturing method and photovoltaic module frame provided by the embodiment of the present application at least facilitate to improve the strength of photovoltaic module frame.

Description

Technical Field

[0001] This application relates to the field of photovoltaic module technology, and in particular to a method for manufacturing a photovoltaic module frame and a photovoltaic module frame. Background Technology

[0002] As a component of photovoltaic (PV) modules, the frame of a PV module secures and seals the PV laminate, enhances the bending strength of the PV module, extends its lifespan, and facilitates transportation and installation. The frame typically consists of a receiving groove and a cavity. The receiving groove engages and holds the laminate, while the cavity secures the PV module frame.

[0003] However, there is currently a problem with the insufficient strength of photovoltaic module frames. Summary of the Invention

[0004] This application provides a method for manufacturing a photovoltaic module frame and a photovoltaic module frame, which at least helps to improve the strength of the photovoltaic module frame.

[0005] According to some embodiments of this application, one aspect of this application provides a method for manufacturing a photovoltaic module frame, comprising: providing a reinforcing layer; adding glass fiber and the reinforcing layer into a molding die containing resin; curing the glass fiber, the reinforcing layer, and the resin in the molding die; pultruding a pultruded profile from the outlet of the molding die using a traction device, wherein the pultruded profile includes the reinforcing layer and the resin and glass fiber covering the reinforcing layer; and cutting the pultruded profile to obtain a photovoltaic module frame, wherein the mass fraction of the reinforcing layer in the formed photovoltaic module frame is 10% to 50%.

[0006] In some embodiments, the step of providing the reinforcing layer includes: providing a reinforcing portion; and bending the reinforcing portion using a cold bending forming process to obtain the reinforcing layer.

[0007] In some embodiments, before adding the reinforcing layer to the molding die containing the resin, the method further includes: dividing the reinforcing layer into a plurality of sub-reinforcing layers, each of the sub-reinforcing layers being used to form a different portion of the photovoltaic module frame, and in the formed photovoltaic module frame, adjacent sub-reinforcing layers having different extension directions.

[0008] According to some embodiments of this application, another aspect of this application provides a photovoltaic module frame, including: a top support portion, a first limiting portion, and a second limiting portion, wherein the first limiting portion is directly opposite to the top support portion, and the top support portion, the second limiting portion, and the first limiting portion are sequentially joined to form a receiving groove; a first side portion, a second side portion, and a bottom support portion, wherein the top support portion, the first side portion, the bottom support portion, and the second side portion are sequentially joined to form a cavity, the top support portion is located between the cavity and the receiving groove, and the second side portion is connected to the second limiting portion; wherein the photovoltaic module frame includes glass fiber, resin, and a reinforcing layer, the reinforcing layer includes a first reinforcing layer, and at least the second limiting portion and the second side portion include the first reinforcing layer, and the resin and the glass fiber cover the first reinforcing layer.

[0009] In some embodiments, the first reinforcing layer is also located in the first limiting portion.

[0010] In some embodiments, the first reinforcing layer is also located in the bottom support portion.

[0011] In some embodiments, the top support portion and the first side portion further include a second reinforcing layer, wherein the resin and the glass fiber cover the second reinforcing layer.

[0012] In some embodiments, the first reinforcing layer and the second reinforcing layer are an integral structure.

[0013] In some embodiments, the first reinforcing layer and the second reinforcing layer are independent structures.

[0014] In some embodiments, the area of ​​the first reinforcing layer is a first area in the extension direction perpendicular to the first reinforcing layer, and the area of ​​the second reinforcing layer is a second area in the extension direction perpendicular to the second reinforcing layer, wherein the first area is greater than or equal to the second area.

[0015] In some embodiments, the material of the first reinforcing layer is a metal, wood, plastic, or rubber.

[0016] The technical solution provided in this application has at least the following advantages:

[0017] The photovoltaic module frame manufacturing method provided in this application uses glass fiber, a reinforcing layer, and resin as raw materials, and obtains the photovoltaic module frame through processes such as pultrusion. Compared with the method of obtaining the photovoltaic module frame through processes such as pultrusion using glass fiber and resin as raw materials, this application embodiment also adds a reinforcing layer as a raw material for making the photovoltaic module frame, so that the formed photovoltaic module frame has a structure of glass fiber and resin covering the reinforcing layer, which can improve the strength of the formed photovoltaic module frame. Furthermore, by adjusting the mass fraction of the reinforcing layer of the photovoltaic module frame to be in the range of 10% to 50%, the strength of the photovoltaic module frame can be kept within a better range. Attached Figure Description

[0018] One or more embodiments are illustrated by way of example with corresponding pictures in the accompanying drawings. These illustrations do not constitute a limitation on the embodiments. Unless otherwise stated, the pictures in the accompanying drawings do not constitute a limitation on scale. In order to more clearly illustrate the technical solutions in the embodiments of this application or in the conventional technology, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 A flowchart illustrating a method for manufacturing a photovoltaic module frame according to an embodiment of this application;

[0020] Figure 2 This is a schematic diagram of the structure of a photovoltaic module frame provided in another embodiment of this application;

[0021] Figure 3 This is a schematic diagram of the structure of a photovoltaic module frame provided in another embodiment of this application;

[0022] Figure 3 This is a schematic diagram of the structure of a photovoltaic module frame provided in another embodiment of this application;

[0023] Figure 4 This is a schematic diagram of the structure of a photovoltaic module frame provided in another embodiment of this application;

[0024] Figure 5 for Figure 4 The cross-sectional views of the first and second reinforcing layers are shown.

[0025] Figure 6 This is a schematic diagram of the structure of a photovoltaic module frame provided in another embodiment of this application;

[0026] Figure 7 for Figure 6 The cross-sectional views of the first and second reinforcing layers are shown.

[0027] Figure 8 This is a schematic diagram of the structure of a photovoltaic module frame provided in another embodiment of this application;

[0028] Figure 9 for Figure 8 The cross-sectional views of the first and second reinforcing layers are shown.

[0029] Figure 10 This is a schematic diagram of the structure of a photovoltaic module frame provided in another embodiment of this application;

[0030] Figure 11 for Figure 10 The cross-sectional views of the first and second reinforcing layers are shown.

[0031] Figure 12 This is a schematic diagram of the structure of a photovoltaic module frame provided in another embodiment of this application;

[0032] Figure 13 This is a schematic diagram of the structure of a photovoltaic module frame provided in another embodiment of this application. Detailed Implementation

[0033] As can be seen from the background technology, the bending strength of photovoltaic module frames still needs to be improved.

[0034] This application provides a method for manufacturing a photovoltaic module frame. The method uses glass fiber, a reinforcing layer, and resin as raw materials, and obtains the photovoltaic module frame through processes such as pultrusion. Compared to using glass fiber and resin as raw materials and obtaining the photovoltaic module frame through processes such as pultrusion, this application embodiment further incorporates a reinforcing layer as the raw material for the photovoltaic module frame. This results in a photovoltaic module frame with a structure where the reinforcing layer is covered by glass fiber and resin, which improves the strength of the formed photovoltaic module frame. Furthermore, by adjusting the mass fraction of the reinforcing layer in the photovoltaic module frame to be within the range of 10% to 50%, the strength of the photovoltaic module frame can be kept within a preferred range.

[0035] The embodiments of this application will now be described in detail with reference to the accompanying drawings. However, those skilled in the art will understand that many technical details have been provided in the embodiments of this application to facilitate a better understanding of the application. However, the technical solutions claimed in this application can be implemented even without these technical details and various variations and modifications based on the following embodiments.

[0036] Figure 1 A flowchart illustrating a method for manufacturing a photovoltaic module frame according to an embodiment of this application.

[0037] refer to Figure 1 S10: Provides a reinforcement layer.

[0038] Understandably, photovoltaic (PV) module frames made from glass fiber and resin through a pultrusion process have relatively low strength. This makes them prone to detachment or tearing when the PV module frame is used to support the PV module, or when exposed to strong winds or other severe weather conditions or significant external forces. In contrast, PV module frames without a reinforcing layer, where the reinforcing layer is the raw material and manufactured through processes like pultrusion, have a structure consisting of glass fiber and resin-coated reinforcing layers. This structure significantly improves the strength of the PV module frame and reduces the likelihood of detachment or tearing.

[0039] The step of providing the reinforcing layer may include: providing a reinforcing portion; and bending the reinforcing portion using a cold bending forming process to obtain the reinforcing layer. In this way, by bending the reinforcing portion to obtain the reinforcing layer of the desired shape, the difficulty of subsequent pultrusion processing of the reinforcing layer can be reduced.

[0040] In some embodiments, the material of the reinforcing part may include metal, wood, plastic, or rubber. For example, the material of the reinforcing part may be iron; for example, the material of the reinforcing part may be stainless steel; and for example, the material of the reinforcing part may be rubber.

[0041] Subsequent steps may further include adding glass fiber and a reinforcing layer into a molding die containing resin, curing the glass fiber, reinforcing layer, and resin, and obtaining a photovoltaic module frame through a pultrusion process. In some embodiments, before adding the reinforcing layer into the molding die containing resin, the reinforcing layer may be divided into multiple sub-reinforcing layers. Each sub-reinforcing layer is bent into a different shape according to the shape of different parts of the photovoltaic module frame to form different parts of the photovoltaic module frame. In the formed photovoltaic module frame, adjacent sub-reinforcing layers have different extension directions depending on the part where each sub-reinforcing layer is located. This helps to reduce the process difficulty of pultruding the pultruded profile in the subsequent step.

[0042] refer to Figure 1 S11: Add glass fiber and reinforcing layer into a molding die containing resin.

[0043] The resin can be polyurethane resin, used to bond glass fibers and reinforcing layers.

[0044] refer to Figure 1 S12: Glass fiber, reinforcing layer and resin are cured in the molding mold.

[0045] It is understandable that glass fibers can improve the strength of the formed photovoltaic module frame. However, if the ratio of the mass fraction of glass fiber to the mass fraction of resin is too large, it will affect the uniformity of the distribution of glass fibers in the resin, which is detrimental to improving the strength of the photovoltaic module frame. In some embodiments, the ratio of the mass fraction of glass fiber to the mass fraction of resin can be 2.5 to 3.5, for example, 2.52, 2.77, 3.1, or 3.49. Within this range, the glass fibers can be more uniformly distributed in the resin, which is beneficial to improving the strength of the formed photovoltaic module frame.

[0046] The curing temperature can be between 60℃ and 80℃. For example, the curing temperature can be 60℃, 62℃, 65℃, 70℃, 75.5℃, or 80℃. It is understood that the glass fiber, reinforcing layer, and resin need to be cured and molded under certain temperature conditions. Too low a curing temperature is detrimental to the curing of the glass fiber, reinforcing layer, and resin, while too high a curing temperature may lead to over-curing of the glass fiber, reinforcing layer, and resin, which is not conducive to the traction of the subsequent traction device. The curing temperature range provided in this embodiment can meet the temperature requirements for the curing of the glass fiber, reinforcing layer, and resin, and is also beneficial for the traction device to pull the molded pultruded profile from the exit of the pultrusion die.

[0047] refer to Figure 1 S13: A pultruded profile formed by being pulled from the outlet of a forming die by a traction device, wherein the pultruded profile includes a reinforcing layer and resin and glass fiber covering the reinforcing layer.

[0048] refer to Figure 1 S14: Cut the pultruded profile to obtain the photovoltaic module frame.

[0049] Refer to the table below for the impact of different components of the reinforcing layer on the bending strength and cost of the photovoltaic module frame. The table below takes iron as the material of the reinforcing layer as an example, and uses the cost of making a photovoltaic module frame without a reinforcing layer as the standard quantity 1 to record the impact of different components of the reinforcing layer on the cost of making the photovoltaic module frame.

[0050]

[0051] Referring to the table above, the data provided in Examples 1, 2, 3, 4, 5, and Comparative Example 1 show that, compared to a photovoltaic module frame without a reinforcing layer, a photovoltaic module frame with a reinforcing layer of a certain mass fraction has greater bending strength. Furthermore, the data from Examples 1 to 3 show that increasing the mass fraction of the reinforcing layer can improve the bending strength of the resulting photovoltaic module frame. However, the data from Examples 4, 5, Comparative Example 2, 3, 4, and 5 show that if the reinforcing layer has an excessive mass fraction in the photovoltaic module frame, it will reduce the mass fraction of glass fiber and resin in the frame. During the process of using the photovoltaic module frame to support the photovoltaic module, because the mass fraction of glass fiber and resin wrapped around the reinforcing layer in the frame is too small, the glass fiber and resin wrapping the reinforcing layer cannot withstand too much force, easily leading to tearing or detachment of the photovoltaic module frame, thus reducing the bending strength of the photovoltaic module frame. Therefore, the mass fraction of the reinforcing layer in the photovoltaic module frame is within the range of 10% to 50%. For example, the mass fraction of the reinforcing layer can be 10.5%, 24%, 33%, 43%, or 47%. Within this range, compared with a photovoltaic module frame without a reinforcing layer, the strength of the formed photovoltaic module frame can be improved, and the mass fraction of the reinforcing layer in the photovoltaic module frame should not be too large, thereby reducing the possibility of the photovoltaic module frame tearing or detachment.

[0052] Referring to the data provided in Examples 1 to 5 and Comparative Examples 1 to 5 in the table above, it can also be seen that in some embodiments, when the reinforcing layer is made of iron, the cost of manufacturing the photovoltaic module frame increases with the increase of the mass fraction of the reinforcing layer in the photovoltaic module frame. By setting the mass fraction of the reinforcing layer in the photovoltaic module frame within the range of 10% to 50%, the cost of manufacturing the photovoltaic module frame can be controlled while effectively improving the strength of the photovoltaic module frame.

[0053] Accordingly, another embodiment of this application also provides a photovoltaic module frame, which can be manufactured by the manufacturing method of the photovoltaic module frame provided in the foregoing embodiment. The photovoltaic module frame provided in another embodiment of this application will be described in detail below with reference to the accompanying drawings. For parts that are the same as or corresponding to the previous embodiment, please refer to the corresponding descriptions in the foregoing embodiments; detailed descriptions will not be repeated below.

[0054] Figure 2 This is a schematic diagram of the structure of a photovoltaic module frame provided in another embodiment of this application. Figure 3 This is a schematic diagram of the structure of a photovoltaic module frame provided in another embodiment of this application. Figure 3 This is a schematic diagram of the structure of a photovoltaic module frame provided in another embodiment of this application. Figure 4 This is a schematic diagram of the structure of a photovoltaic module frame provided in another embodiment of this application. Figure 5 for Figure 4 The cross-sectional views of the first and second reinforcing layers shown are as follows. Figure 6 This is a schematic diagram of the structure of a photovoltaic module frame provided in another embodiment of this application. Figure 7 for Figure 6 The cross-sectional views of the first and second reinforcing layers shown are as follows. Figure 8 This is a schematic diagram of the structure of a photovoltaic module frame provided in another embodiment of this application. Figure 9 for Figure 8 The cross-sectional views of the first and second reinforcing layers shown are as follows. Figure 10 This is a schematic diagram of the structure of a photovoltaic module frame provided in another embodiment of this application. Figure 11 for Figure 10 The cross-sectional views of the first and second reinforcing layers shown are as follows. Figure 12 This is a schematic diagram of the structure of a photovoltaic module frame provided in another embodiment of this application. Figure 13 This is a schematic diagram of the structure of a photovoltaic module frame provided in another embodiment of this application.

[0055] refer to Figure 2 The photovoltaic module frame includes: a top support portion 101, a first limiting portion 102, and a second limiting portion 103, wherein the first limiting portion 102 is directly opposite the top support portion 101, and the top support portion 101, the second limiting portion 103, and the first limiting portion 102 are sequentially joined to form a receiving groove 104; a first side portion 105, a second side portion 106, and a bottom support portion 107, wherein the top support portion 101, the first side portion 105, the bottom support portion 107, and... The second side portions 106 sequentially connect to form the cavity 108, the top supporting portion 101 is located between the cavity 108 and the receiving groove 104, and the second side portions 106 are connected to the second limiting portion 103; wherein, the photovoltaic module frame includes glass fiber, resin and a reinforcing layer, the reinforcing layer includes a first reinforcing layer 109, and at least the second limiting portion 103 and the second side portions 106 include the first reinforcing layer 109, and the resin and glass fiber cover the first reinforcing layer 109. Thus, by providing the first reinforcing layer 109 at least in the second limiting portion 103 and the second side portions 106 of the photovoltaic module frame, forming a structure in the second limiting portion 103 and the second side portions 106 where the glass fiber and resin cover the first reinforcing layer 109, the strength of the second limiting portion 103 and the second side portions 106 of the photovoltaic module frame can be improved at least.

[0056] It is understandable that when a photovoltaic module frame without a reinforcing layer is used to support the photovoltaic module, the second limiting part 103 and the second side part 106 bear greater pressure than the rest of the photovoltaic module frame. The second limiting part 103 and the second side part 106 are prone to tearing due to excessive pressure. To prevent the second limiting part 103 and the second side part 106 from tearing due to excessive pressure, a first reinforcing layer 109 is provided on the second limiting part 103 and the second side part 106. This increases the strength of the second limiting part 103 and the second side part 106, thereby preventing tearing and improving the overall strength of the photovoltaic module frame.

[0057] In the frame of a photovoltaic module, the resin can be polyurethane resin, used to bond glass fibers and reinforcing layers.

[0058] It is understandable that glass fiber can improve the strength of photovoltaic module frames. However, if the ratio of the mass fraction of glass fiber to the mass fraction of resin is too small, the strength of the photovoltaic module frame will be too low; if the ratio is too large, it will affect the uniformity of the distribution of glass fiber in the resin, which is not conducive to improving the strength of the photovoltaic module frame. In some embodiments, the ratio of the mass fraction of glass fiber to the mass fraction of resin can be 2.5 to 3.5, for example, 2.52, 2.77, 3.1 or 3.49. Within this range, the glass fiber can be more uniformly distributed in the resin, which is beneficial to improving the strength of the photovoltaic module frame.

[0059] The mass fraction of the reinforcing layer in the photovoltaic module frame can be 10% to 50%. For example, the mass fraction of the reinforcing layer can be 10.5%, 24%, 33%, 43%, or 47%. Within this range, the strength of the formed photovoltaic module frame can be improved, and the photovoltaic module frame can be prevented from tearing or detaching due to the glass fiber and resin wrapped in the reinforcing layer being unable to withstand too much force during the photovoltaic module frame bearing the photovoltaic module.

[0060] The reinforcing layer can be made of metal, wood, plastic, or rubber. Specifically, the first reinforcing layer 109 can be made of metal, wood, plastic, or rubber. For example, the first reinforcing layer 109 can be made of iron; for example, the first reinforcing layer 109 can be made of stainless steel; and for example, the first reinforcing layer 109 can be made of rubber.

[0061] The receiving groove 104 of the photovoltaic module frame can support the photovoltaic module. In some embodiments, at least one recess 112 can be provided on the surface of the first limiting part 102 facing the receiving groove 104, so that the surface of the first limiting part 102 facing the receiving groove 104 has a concave-convex structure. In this way, when the photovoltaic module is snapped into the receiving groove 104, a cavity can be formed between the concave-convex structure of the first limiting part 102 facing the top bearing part 101 and the surface of the photovoltaic module. This cavity can serve as a glue reservoir for storing excess sealant, which can not only improve the glue overflow phenomenon, but also increase the amount of sealant stored to improve the bonding strength. On the other hand, the concave-convex structure of the surface of the first limiting part 102 facing the glue reservoir can play an anti-slip role, further improving the bonding strength of the receiving groove 104 to the photovoltaic module.

[0062] In some embodiments, the photovoltaic module frame may further include corner brackets (not shown), and the cavity 108 may be used to accommodate the corner brackets to form a continuous photovoltaic module assembly structure. The photovoltaic module frame may further include at least one protrusion 113, which may be located on the surface of the top support portion 101 or the bottom support portion 107 facing the cavity 108. By providing the protrusion 113, it can be ensured that the corner brackets in the cavity 108 are not easily misaligned with the photovoltaic module frame.

[0063] refer to Figure 3 In some embodiments, the first reinforcing layer 109 may be disposed in the second limiting portion 103 and the second side portion 106, or it may be located in the first limiting portion 102 to increase the strength of the first limiting portion 102.

[0064] refer to Figure 3 In some embodiments, the first reinforcing layer 109 may be disposed in the second limiting portion 103 and the second side portion 106, or it may be located in the bottom bearing portion 107 to increase the strength of the bottom bearing portion 107.

[0065] It is understood that the first reinforcing layer 109 may be located in the second limiting part 103 and the second side part 106, and may also be located in the first limiting part 102, or the first reinforcing layer 109 may be located in the second limiting part 103 and the second side part 106, and may also be located in the bottom bearing part 107.

[0066] refer to Figure 4 and Figure 8 In some embodiments, the top support portion 101 and the first side portion 105 may further include a second reinforcing layer 110, which is covered with resin and glass fiber. Thus, by providing the second reinforcing layer 110 in the top support portion 101 and the first side portion 105, the strength of the top support portion 101 and the first side portion 105 can be enhanced.

[0067] refer to Figure 4 In some embodiments, the first reinforcing layer 109 and the second reinforcing layer 110 can be an integral structure, that is, one end of the first reinforcing layer 109 is connected to one end of the second reinforcing layer 110.

[0068] Wherein, in the extension direction perpendicular to the first reinforcing layer 109, the area of ​​the first reinforcing layer 109 is the first area, and in the extension direction perpendicular to the second reinforcing layer 110, the area of ​​the second reinforcing layer 110 is the second area.

[0069] refer to Figure 4 and Figure 5 ,in, Figure 5 Figure (a) is Figure 4 The cross-sectional view of the first reinforcing layer 109 shown is perpendicular to the extension direction of the first reinforcing layer 109. Figure 5 Figure (b) is Figure 4 The diagram shows a cross-sectional view of the second reinforcing layer 110 perpendicular to its extension direction. In some embodiments, the first area can be larger than the second area to improve the overall strength of the photovoltaic module frame and prevent the second limiting portion 103 and the second side portion 106 from tearing due to insufficient pressure. The ratio of the first area to the second area can be between 1.5 and 2.5, for example, 1.51, 1.92, 2, or 2.48. Within this range, the strength of the photovoltaic module frame can be enhanced, resulting in greater strength for the second limiting portion 103 and the second side portion 106. This allows the second limiting portion 103 and the second side portion 106 to withstand greater pressure, while avoiding excessively large first areas that would increase the cost of forming the photovoltaic module frame.

[0070] refer to Figure 6 and Figure 7 ,in, Figure 7 Figure (a) is Figure 6 The cross-sectional view of the first reinforcing layer 109 shown is perpendicular to the extension direction of the first reinforcing layer 109. Figure 7 Figure (b) is Figure 6 The diagram shows a cross-sectional view of the second reinforcing layer 110 perpendicular to its extension direction. In some embodiments, the first area can be equal to the second area, which can also improve the strength of the photovoltaic module frame.

[0071] refer to Figure 8 In some embodiments, the first reinforcing layer 109 and the second reinforcing layer 110 can be independent structures. Compared with embodiments where the first reinforcing layer 109 and the second reinforcing layer 110 are an integral structure, the first reinforcing layer 109 and the second reinforcing layer 110 are independent in this embodiment, which helps to reduce the difficulty of the pultrusion process in forming the photovoltaic module frame.

[0072] Wherein, in the extension direction perpendicular to the first reinforcing layer 109, the area of ​​the first reinforcing layer 109 is the first area, and in the extension direction perpendicular to the second reinforcing layer 110, the area of ​​the second reinforcing layer 110 is the second area.

[0073] refer to Figure 8 and Figure 9 ,in, Figure 9 Figure (a) is Figure 8 The cross-sectional view of the first reinforcing layer 109 shown is perpendicular to the extension direction of the first reinforcing layer 109. Figure 9 Figure (b) is Figure 8 The diagram shows a cross-sectional view of the second reinforcing layer 110 perpendicular to its extension direction. In some embodiments, the first area can be larger than the second area, which can enhance the strength of the photovoltaic module frame and make the strength of the second limiting portion 103 and the second side portion 106 greater. This allows the second limiting portion 103 and the second side portion 106 to withstand greater pressure, while avoiding the high cost of forming the photovoltaic module frame due to an excessively large first area.

[0074] refer to Figure 10 and Figure 11 ,in, Figure 11 Figure (a) is Figure 10 The cross-sectional view of the first reinforcing layer 109 shown is perpendicular to the extension direction of the first reinforcing layer 109. Figure 11 Figure (b) is Figure 10 The diagram shows a cross-sectional view of the second reinforcing layer 110 perpendicular to its extension direction. In some embodiments, the first area can be equal to the second area, which can also improve the strength of the photovoltaic module frame.

[0075] It is understood that the first reinforcing layer 109 can also be an intermittent film layer. For example, the first reinforcing layer 109 is located in the second limiting portion 103 and the second side portion 106 and is covered by glass fiber and resin. Each film layer is arranged in the extending direction along the second limiting portion 103 and the second side portion 106, which can also improve the strength of the second limiting portion 103 and the second side portion 106. The second reinforcing layer 110 can also be an intermittent film layer. For example, the second reinforcing layer 110 is located in the top bearing portion 101 and the first limiting portion 102. Each film layer is arranged in the extending direction along the top bearing portion 101 and the first limiting portion 102, which can also improve the strength of the top bearing portion 101 and the first limiting portion 102.

[0076] It is also understood that the photovoltaic module frame can be provided with at least 3 sub-reinforcing layers, each sub-reinforcing layer is located in a part of the photovoltaic module frame, and the area of ​​each sub-reinforcing layer can be equal in the corresponding extension direction perpendicular to each sub-reinforcing layer, or the area of ​​the sub-reinforcing layer located in the second limiting part 103 and the area of ​​the sub-reinforcing layer located in the second side part 106 can be greater than the area of ​​the sub-reinforcing layers in the rest of the photovoltaic module frame.

[0077] refer to Figure 12 In some embodiments, the photovoltaic module frame may include a first reinforcing layer 109, a second reinforcing layer 110, and a third reinforcing layer 111. The first reinforcing layer 109 is located in the second limiting portion 103 and the second side portion 106, the second reinforcing layer 110 is located in the first limiting portion 102, and the third reinforcing layer 111 is located in the top supporting portion 101, the first side portion 105, and the bottom supporting portion 107.

[0078] In this design, the area of ​​the first reinforcing layer 109 is a first area in the extension direction perpendicular to the first reinforcing layer 109; the area of ​​the second reinforcing layer 110 is a second area in the extension direction perpendicular to the second reinforcing layer 110; and the area of ​​the third reinforcing layer 111 is a third area in the extension direction perpendicular to the third reinforcing layer 111. In some embodiments, the first area can be larger than the second area, and the first area can be larger than the third area, while the second area is equal to the third area. This enhances the strength of the photovoltaic module frame and makes the strength of the second limiting portion 103 and the second side portion 106 greater, thereby enabling the second limiting portion 103 and the second side portion 106 to withstand greater pressure and avoiding excessively large first areas that would result in high costs for forming the photovoltaic module frame. In some embodiments, the first area can be equal to the second area, and the first area can also be equal to the third area, which also improves the overall strength of the photovoltaic module frame.

[0079] It is also understandable that the photovoltaic module frame can be provided with multiple sub-reinforcing layers, wherein at least a portion of the photovoltaic module frame has multiple sub-reinforcing layers.

[0080] refer to Figure 13The photovoltaic module frame includes a first reinforcing layer 109, a second reinforcing layer 110, and a third reinforcing layer 111. The first reinforcing layer 109 is located in the second limiting portion 103 and the second side portion 106, and the third reinforcing layer 111 is also located in the second limiting portion 103 and the second side portion 106. The second reinforcing layer 110 is located in the top supporting portion 101 and the first side portion 105. The first reinforcing layer 109 and the third reinforcing layer 111 are arranged at intervals along the extension direction of the second limiting portion 103 and along the extension direction of the second side portion 106, and are both covered with resin and glass fiber. The area of ​​the first reinforcing layer 109 is a first area along the extension direction of the first reinforcing layer 109, the area of ​​the second reinforcing layer 110 is a second area along the extension direction perpendicular to the extension direction of the second reinforcing layer 110, and the area of ​​the third reinforcing layer 111 is a third area along the extension direction perpendicular to the extension direction of the third reinforcing layer 111. Thus, compared to the implementation where each area of ​​the photovoltaic module frame has at most one sub-reinforcing layer, the first reinforcing layer 109 and the third reinforcing layer 111 provided in this embodiment have smaller first and second areas, which helps to reduce the difficulty of bending each sub-reinforcing layer into different shapes.

[0081] In this design, the sum of the first and third areas can be greater than the second area, which enhances the strength of the photovoltaic module frame and makes the strength of the second limiting portion 103 and the second side portion 106 greater. This allows the second limiting portion 103 and the second side portion 106 to withstand greater pressure, while avoiding excessively large first areas that would lead to high costs in forming the photovoltaic module frame. In some embodiments, the sum of the first and third areas can also be equal to the second area, which also helps to improve the overall strength of the photovoltaic module frame.

[0082] Continue to refer to Figure 13 In some embodiments, the first reinforcing layer 109, the second reinforcing layer 110, and the third reinforcing layer 111 can all be independent structures.

[0083] It is understood that in some embodiments, one end of the first reinforcing layer 109 or one end of the third reinforcing layer 111 may also be connected to the second reinforcing layer 110. In some embodiments, one end of the first reinforcing layer 109 and one end of the third reinforcing layer 111 may both be connected to the second reinforcing layer 110, that is, the first reinforcing layer 109, the second reinforcing layer 110 and the third reinforcing layer 111 may be an integral structure.

[0084] The photovoltaic module frame provided in the above embodiment is made of resin and glass fiber, and a first reinforcing layer 109 is provided in at least the second limiting portion 103 and the second side portion 106 of the photovoltaic module frame. The first reinforcing layer 109 is covered by glass fiber and resin. Compared with a photovoltaic module frame without the first reinforcing layer 109, the photovoltaic module frame provided in this embodiment has greater strength. In addition, a second reinforcing layer 110 can be provided in the top supporting portion 101 and the first side portion 105 to improve the strength of the top supporting portion 101 and the first side portion 105, thereby improving the overall strength of the photovoltaic module frame.

[0085] Those skilled in the art will understand that the above embodiments are specific examples of implementing this application, and in practical applications, various changes in form and detail can be made without departing from the spirit and scope of this application. Any person skilled in the art can make various alterations and modifications without departing from the spirit and scope of this application; therefore, the scope of protection of this application should be determined by the scope defined in the claims.

Claims

1. A photovoltaic module frame, characterized in that, include: The top support portion, the first limiting portion, and the second limiting portion are provided, wherein the first limiting portion is directly opposite the top support portion, and the top support portion, the second limiting portion, and the first limiting portion are sequentially joined together to form a receiving groove. The photovoltaic module comprises a first side portion, a second side portion, and a bottom supporting portion, wherein the top supporting portion, the first side portion, the bottom supporting portion, and the second side portion are sequentially joined to form a cavity. The top supporting portion is located between the cavity and the receiving groove, and the second side portion is connected to the second limiting portion. The photovoltaic module frame includes glass fiber, resin, and a reinforcing layer. The reinforcing layer includes a first reinforcing layer and a second reinforcing layer, and at least the second limiting portion and the second side portion include the first reinforcing layer. The resin and the glass fiber cover the first reinforcing layer. The top supporting portion and the first side portion also include the second reinforcing layer, which is covered by the resin and the glass fiber. In the extension direction perpendicular to the first reinforcing layer, the cross-section of the first reinforcing layer is circular, and the area of ​​the first reinforcing layer is a first area. In the extension direction perpendicular to the second reinforcing layer, the cross-section of the second reinforcing layer is circular, and the area of ​​the second reinforcing layer is a second area. The first area is greater than or equal to the second area. The first reinforcing layer and the second reinforcing layer extend along the circumferential direction of the cavity. The materials of the first reinforcing layer and the second reinforcing layer are metallic.

2. The photovoltaic module frame as described in claim 1, characterized in that, The first reinforcing layer is also located in the first limiting part.

3. The photovoltaic module frame as described in claim 1, characterized in that, The first reinforcing layer is also located in the bottom bearing portion.

4. The photovoltaic module frame as described in claim 1, wherein the first reinforcing layer and the second reinforcing layer are an integral structure.

5. The photovoltaic module frame as described in claim 1, characterized in that, The first reinforcing layer and the second reinforcing layer are independent structures.

6. A method for manufacturing a photovoltaic module frame, characterized in that, include: Provide a reinforcement layer; Glass fiber and the reinforcing layer are added to a molding die containing resin; The glass fiber, the reinforcing layer, and the resin are cured in the molding mold. The reinforcing layer is made of metal. The reinforcing layer includes a first reinforcing layer and a second reinforcing layer. The first reinforcing layer has a circular cross-section and a first area along the extension direction perpendicular to the first reinforcing layer. The second reinforcing layer has a circular cross-section and a second area along the extension direction of the second reinforcing layer. The first area is greater than or equal to the second area. A pultruded profile is formed by being pulled out of the mold by a traction device, wherein the pultruded profile includes a reinforcing layer and the resin and the glass fiber covering the reinforcing layer, and the first reinforcing layer and the second reinforcing layer extend along the circumferential direction of the cavity of the pultruded profile; The pultruded profile is cut to obtain a photovoltaic module frame as described in any one of claims 1 to 5, wherein the mass fraction of the reinforcing layer in the formed photovoltaic module frame is 10% to 50%.

7. The method for manufacturing a photovoltaic module frame as described in claim 6, characterized in that, The step of providing the reinforcing layer includes: providing a reinforcing portion; and bending the reinforcing portion using a cold bending forming process to obtain the reinforcing layer.

8. The method for manufacturing a photovoltaic module frame as described in claim 6, characterized in that, Before adding the reinforcing layer into the molding die containing the resin, the method further includes: dividing the reinforcing layer into a plurality of sub-reinforcing layers, each of the sub-reinforcing layers being used to form a different portion of the photovoltaic module frame, and in the formed photovoltaic module frame, adjacent sub-reinforcing layers having different extension directions.

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