A method for manufacturing aluminum material for solar photovoltaic support

Abstract

This invention relates to the field of photovoltaic product components, specifically to a method for manufacturing aluminum material for solar photovoltaic load-bearing, comprising the following steps: a) taking an aluminum alloy ingot and forming it by extrusion molding to form a profile with the following cross-sectional structure: an outer side and an inner side extending vertically, an upper top edge and a lower top edge connecting the outer side and the inner side, the upper end of the outer side having an extending edge, and the middle of the inner side extending horizontally to a bottom edge; b) performing intermittent partial cutting on the profile to form intermittently distributed retained sections and cut sections, and cutting along the middle of the retained sections, so that each cut profile has four cut sections; c) bending the profile after step b along the cut section positions using a bending mechanism, resulting in a rounded rectangular structure. This invention solves the problem of poor installation convenience on existing photovoltaic panels.

Description

Technical Field

[0001] This invention relates to the field of components for photovoltaic products, and specifically to a method for manufacturing aluminum materials for solar photovoltaic load-bearing. Background Technology

[0002] Solar photovoltaic panels are devices that absorb sunlight and convert it into electrical energy through the photoelectric effect. Structurally, they generally include tempered glass, solar cells, and a backsheet. These components are reinforced with materials such as EVA, and then assembled into a whole by a frame that supports the structure. At the same time, silicone and other materials are added for sealing to protect electrical components such as junction boxes.

[0003] In existing structures, such as the aluminum alloy profile for a solar photovoltaic cell frame disclosed in Chinese Patent CN 202150467 U, the structure is composed of a top edge, bottom edge, side edge, middle edge, reinforcing edge, slot, and rib, as shown in the cross-section of one end of the aluminum alloy profile for the solar photovoltaic cell frame. The slot is used to clamp a protective tempered glass panel, while the bottom and middle edges are used to install the solar photovoltaic panel.

[0004] In the above structure, both the protective tempered glass panel and the photovoltaic panel need to be inserted into the corresponding grooves to complete the installation, which is quite inconvenient under the current structure. Summary of the Invention

[0005] Therefore, the present invention provides a method for manufacturing aluminum material for solar photovoltaic support, which solves the problem of poor installation convenience on existing photovoltaic panels.

[0006] To achieve the above objectives, the present invention is implemented through the following technical solution:

[0007] A method for manufacturing an aluminum material for solar photovoltaic support includes the following steps:

[0008] a. Take an aluminum alloy ingot and form it by extrusion molding to form a profile with the following cross-section structure: an outer side and an inner side extending vertically along the profile, an upper top edge and a lower top edge connecting the outer side and the inner side, the upper end of the outer side having an extension edge, and the middle part of the inner side extending a bottom edge in the horizontal direction.

[0009] b. Perform intermittent local cutting on the profile to form intermittently distributed retained sections and cutting sections, and cut along the middle of the retained sections so that each cut profile has four cutting sections.

[0010] c. The profile after step b is bent along the cutting section using a bending mechanism, resulting in a rounded rectangular profile structure.

[0011] d. Fix the half-sections at both ends of the profile after step c using a connector to obtain the aluminum material for solar photovoltaic support.

[0012] Preferably, the portion cut off by the cutting segment is the bottom edge, which is an isosceles trapezoid in shape, and the bottom edges on both sides of the cutting segment abut against each other after step c.

[0013] Preferably, the cutting segment is a transverse cut along the bottom edge, and the bottom edges on both sides of the cut are staggered in height and stacked after step c.

[0014] Preferably, the cut extends to the inner side and cuts it to form a slot that facilitates bending.

[0015] Preferably, the bending mechanism includes a frame on which a main pressure roller and two side pressure rollers symmetrically arranged on both sides are mounted. The main pressure roller and the two side pressure rollers are all fixedly connected to a moving mechanism that drives the three to reciprocate linearly. The angle between the moving trajectory of the two side pressure rollers and the moving trajectory of the main pressure roller is an acute angle. The main pressure roller and the side pressure rollers can both rotate around the center and can achieve independent forward and reverse rotation. A guide block is also provided on the frame. The guide block is located on the frame outside the near ends of the main pressure roller and the two side pressure rollers. The side of the guide block facing the main pressure roller is an arc-shaped guide surface.

[0016] Preferably, the contact surfaces of the side pressure roller, the main pressure roller, and the aluminum material are located on the inner side of the lower end of the bottom edge, and the height of the arc guide surface is higher than the outer side.

[0017] Preferably, the contact surface between the side pressure roller and the aluminum material is located at the inner side of the lower end of the bottom edge, the contact surface between the main pressure roller and the aluminum material is located at the inner side of the upper end of the bottom edge, and the height of the arc guide surface is higher than the outer side.

[0018] Preferably, the angle between the moving trajectories of the two side pressure rollers and the moving trajectories of the main pressure roller is 40-45 degrees.

[0019] By adopting the aforementioned technical solution, the beneficial effects of the present invention are:

[0020] This technical solution features an inclined extension edge structure. In use, the inclined structure, in conjunction with the top edge, forms a locking groove for holding the tempered glass. The tempered glass can be inserted from the opening of the extension edge after the photovoltaic panel frame is assembled. The inclination angle of the extension edge ensures that the tempered glass can be inserted and locked in place after insertion. Then, according to requirements, auxiliary fasteners such as adhesive or adhesive strips can be applied, greatly simplifying the installation difficulty and making the installation structure very flexible.

[0021] The inner and bottom edges form mounting grooves for inserting photovoltaic panels. The upper end of the mounting groove has an open structure, allowing the photovoltaic panel to be placed directly on the bottom edge and then against the inner edge. After the aluminum materials around the photovoltaic panel are installed, a frame structure for the photovoltaic panel is naturally formed. Then, according to the needs, elastic pads or other support structures for buffer support are installed on the bottom edge or inner edge. The installation structure is simple and does not require alignment with a frame with a small opening size as is usually done. This structure does not interfere with the installation of photovoltaic panels and tempered glass. The structure is simple and the installation is very convenient, greatly simplifying the installation steps and reducing labor intensity.

[0022] The frame structure consists of a single piece of aluminum that is bent and wrapped around the photovoltaic panel. The two ends are then fixed with sheet metal as connectors. Tempered glass is then installed from above to complete the installation. This design makes the entire aluminum alloy frame structure more robust, and the bent, integrated structure greatly simplifies the installation process. It is particularly suitable for the production of small-sized photovoltaic panels. In terms of the product, the number of individual photovoltaic panels can be selected according to the area to be covered, allowing for flexible installation and a simple installation structure.

[0023] During production, the production process was improved based on the above structure. The traditional structure of assembling individual aluminum strips with independent frames was modified into a frame structure where individual aluminum strips were bent and shaped into an integrated frame structure. Because it is an integrated structure, the supporting structure of the entire photovoltaic panel is stable and provides good protection for it. Attached Figure Description

[0024] Figure 1 This is a structural schematic diagram of the frame forming process according to Embodiment 1 of the present invention;

[0025] Figure 2 This is a schematic diagram of the cross-sectional structure of the aluminum material in Embodiment 1 of the present invention;

[0026] Figure 3 This is a top view structural diagram of the bending mechanism in Embodiment 1 of the present invention;

[0027] Figure 4 This is a schematic diagram of the positional structure of the main pressure roller and the side pressure roller in Embodiment 1 of the present invention;

[0028] Figure 5 This is a schematic diagram showing the positional structure of the main pressure roller and the side pressure roller in another structure of Embodiment 1 of the present invention;

[0029] Figure 6 This is a schematic diagram of the frame forming process in Embodiment 2 of the present invention;

[0030] Figure 7 This is a side view of the guide cutter structure in Embodiment 2 of the present invention;

[0031] Figure 8 This is a top view of the guide cutter structure in Embodiment 2 of the present invention.

[0032] Reference numerals: 100, base; 101, outer side; 102, inner side; 103, top edge; 104, bottom edge; 105, extension edge; 106, locking groove; 107, bottom edge; 108, mounting groove; 200, connector; 300, notch; 400, guide cutter; 401, longitudinal blade; 402, guide platform; 500, slot; a, retaining section; b, cutting section; 10, frame; 11, main pressure roller; 12, side pressure roller; 13, linear slide rail assembly; 14, guide block; 141, arc guide surface; α, included angle. Detailed Implementation

[0033] The following will describe in detail the implementation of the present invention with reference to specific embodiments, so that the process of how the present invention uses technical means to solve technical problems and achieve technical effects can be fully understood and implemented accordingly.

[0034] Example 1

[0035] refer to Figure 1 As shown, a method for manufacturing an aluminum material for solar photovoltaic support includes the following steps:

[0036] a. Take an aluminum alloy ingot, and form it through an extrusion die to create a profile with the following cross-sectional structure, such as... Figure 2 As shown: the profile has an outer side 101 and an inner side 102 extending vertically, an upper top edge 103 and a lower top edge 104 connecting the outer side 101 and the inner side 102, the upper end of the outer side 101 has an extension edge 105, and the middle part of the inner side 102 extends a bottom edge 107 in the horizontal direction.

[0037] b. Perform intermittent local cutting on the profile to form intermittently distributed retained segments a and cutting segments b, and cut along the middle of the retained segment a, so that each cut profile has four cutting segments b.

[0038] c. The profile after step b is bent along the cutting section b using a bending mechanism, resulting in a rounded rectangular profile structure.

[0039] d. Fix the half-sections a at both ends of the profile after step c using a connector 200 to obtain the aluminum material for solar photovoltaic support.

[0040] In this embodiment, the portion cut off by the cutting segment b is the bottom edge 107, which is an isosceles trapezoid. The edges of the bottom edges 107 on both sides of the cutting segment b abut against each other after step c. The shorter side of the isosceles trapezoid serves as the rounded corner of the bend. When the two bottom edges 107 contact, a certain gap is unavoidable due to limitations in machining accuracy. With this structure, the two bottom edges 107 are on the same plane, ensuring that all four sides of the photovoltaic panel are on the same plane after placement, resulting in good structural support.

[0041] In this embodiment, the bending mechanism is as follows: Figure 3 As shown, the device includes a frame 10, on which a main pressure roller 11 and two side pressure rollers 12 symmetrically arranged on both sides of the main pressure roller 11 are mounted. The main pressure roller 11 and the two side pressure rollers 12 are all fixedly connected to a moving mechanism that drives them in linear reciprocating motion. The angle α between the moving trajectory of the two side pressure rollers 12 and the moving trajectory of the main pressure roller 11 is an acute angle. Both the main pressure roller 11 and the side pressure rollers 12 can rotate around a center and can achieve independent forward and reverse rotation. The main pressure roller 11 and the side pressure rollers 12 are respectively connected to different servo motors. The moving mechanism consists of a linear slide rail assembly 13 and hydraulic cylinders and related transmission components that drive the main pressure roller 11 and the side pressure rollers 12 to move on the linear slide rail assembly 13. (Not shown in the figure); During bending, the aluminum material is supported on the two side pressure rollers 12, that is, between the two side pressure rollers 12 and the main pressure roller 11. The two side pressure rollers 12 rotate in opposite directions, so that the aluminum material receives force towards its two ends; while the main pressure roller 11 moves downward gradually during this process, contacting and squeezing the aluminum material. The bending action is gradually completed as the main pressure roller 11 moves; In production, the midpoint of the cutting section b is placed at the position of the main pressure roller 11's moving path. As the main pressure roller 11 and the side pressure rollers 12 approach each other, the bending of the aluminum alloy is completed in this process. During the bending process, the main pressure roller 11 and the side pressure rollers 12 maintain their rotation to avoid rigid extrusion and ensure the integrity of the appearance of the extruded surface;

[0042] Furthermore, a guide block 14 is also provided on the frame 10. The guide block 14 is located on the frame 10 outside the near ends of the main pressure roller 11 and the two side pressure rollers 12. The side of the guide block 14 facing the main pressure roller 11 is an arc-shaped guide surface 141. The function of the arc-shaped guide surface 141 is to cooperate with the main pressure roller 11 during forming to ensure the angle of the bending radius. In order to ensure production, in the actual design, the diameter of the two side pressure rollers 12 is smaller than the diameter of the main pressure roller 11. As a result, after the two side pressure rollers 12 travel, the cutting section bb of the aluminum profile adheres to the surface of the main pressure roller 11 to form a bending radius, and it will not interfere with the guide block 14. In addition, with the guide block 14, the side pressure rollers 12 play the role of initial bending. Later, after the aluminum alloy is bent, the main pressure roller 11 presses the aluminum profile against the guide block 14, that is, the bending operation is completed by the cooperation of the main pressure roller 11 and the guide block 14.

[0043] Furthermore, after trial production, due to the springback phenomenon of metal, the bending angle needs to be adjusted during production. Specifically, the angle α between the moving trajectory of the two side pressure rollers 12 and the moving trajectory of the main pressure roller 11 is 40-45 degrees. The angle setting here is selected according to the different materials and the different springback amounts. Moreover, the structure of the above-mentioned fastener can also restrict the bent rounded corner structure after bending during production, so that it maintains its shape until welding is completed.

[0044] Structurally, such as Figure 4 As shown, due to the constraints of the bottom edges 107 on both sides, in order to prevent interference with the bending process, the contact surfaces of the side pressure rollers 12 and the main pressure rollers 11 with the aluminum material are located at the inner side edge 102 at the lower end of the bottom edge 107, and the height of the arc guide surface 141 is higher than the outer side edge 101.

[0045] Furthermore, such as Figure 5 As shown, unlike the arrangement of the main pressure roller 11 and side pressure roller 12 described above, the contact surface between the side pressure roller 12 and the aluminum material is located at the inner side 102 of the lower end of the bottom edge 107, while the contact surface between the main pressure roller 11 and the aluminum material is located at the inner side 102 of the upper end of the bottom edge 107. The height of the arc guide surface 141 is higher than that of the outer side 101. Compared with the above structure, this structure ensures that the aluminum material is subjected to force in the thickness direction, and the inner side 102 above the bottom edge 107 can also have a good bending effect during bending.

[0046] This technical solution features an inclined extension edge 105 structure. In use, this inclined structure, together with the top edge 103, forms a locking groove 106 for securing tempered glass. The tempered glass can be inserted through the opening of the extension edge 105 after the photovoltaic panel frame is assembled. The inclination angle of the extension edge 105 ensures that the tempered glass can be inserted and locked in place after insertion. Then, according to requirements, adhesive or strips or other auxiliary fixing components can be applied, greatly simplifying the installation difficulty and making the installation structure very flexible.

[0047] The inner side 102 and the bottom side 107 form an installation groove 108 for installing the photovoltaic panel. The upper end of the installation groove 108 is an open structure, which allows the photovoltaic panel to be placed directly on the bottom side 107 and then abutted against the inner side 102. After the aluminum material around the photovoltaic panel is installed, a frame structure for the photovoltaic panel is naturally formed. Then, according to the needs, elastic pads and other support structures for buffer support are installed on the bottom side 107 or the inner side 102. The installation structure is simple and does not require alignment with a small frame as usual. This structure does not interfere with the installation of the photovoltaic panel and the tempered glass. The structure is simple and the installation is convenient, which greatly simplifies the installation steps and reduces labor intensity.

[0048] The frame structure consists of a single piece of aluminum material that is bent and wrapped around the photovoltaic panel. The two ends are then fixed with sheet metal as connectors 200. Tempered glass is then installed from above to complete the installation. This design makes the entire aluminum alloy frame structure more robust, and the bent, integrated structure greatly simplifies the installation process. It is particularly suitable for the production of small-sized photovoltaic panels. In terms of the product, the number of individual photovoltaic panels can be selected according to the area to be covered, allowing for flexible installation and a simple installation structure.

[0049] During production, the production process was improved based on the above structure. The traditional structure of assembling individual aluminum strips with independent frames was modified into a frame structure where individual aluminum strips were bent and shaped into an integrated frame structure. Because it is an integrated structure, the supporting structure of the entire photovoltaic panel is stable and provides good protection for it.

[0050] Example 2

[0051] refer to Figure 6 Compared to Embodiment 1, the cutting segment b is a transverse cut 300 along the bottom edge 107, with the bottom edges 107 on both sides of the cut 300 being staggered in height and stacked after step c. Wherein, as... Figure 7 , Figure 8 As shown, the aforementioned staggered bottom edge 107 structure is formed by a special guide cutter 400, which has a longitudinal blade 401 at the end and guide platforms 402 on both sides of the longitudinal blade 401. The guide cutter 400 applies force to cut laterally into the bottom edge 107, causing the bottom edges 107 on both sides to deform along the guide platforms 402. The guide platforms 402 are arc-shaped structures, and as the guide cutter 400 gradually penetrates, the bottom edges 107 on both sides bend accordingly, thereby achieving the staggered effect. The guide cutter 400 is force-applied by a corresponding hydraulic cylinder, and the base 100 on the opposite side has corresponding structural support to meet the forming operation.

[0052] Furthermore, the cut 300 extends to the inner side 102 and cuts it open to form a slot 500 that facilitates bending. In order to reduce the difficulty of bending, the cut 300 extends to the inner side 102, and the slot 500 can form a recess for the corner of the photovoltaic panel on one side of the inner side 102, so as to avoid the situation where the corner of the photovoltaic panel cannot be placed into the frame due to excessive bending.

[0053] Although the invention has been specifically shown and described in conjunction with preferred embodiments, those skilled in the art should understand that various changes in form and detail may be made to the invention without departing from the spirit and scope of the invention as defined in the appended claims, all of which shall be within the scope of protection of the invention.

Claims

1. A method for manufacturing an aluminum material for solar photovoltaic support, characterized in that, Includes the following steps: a. Take an aluminum alloy ingot and form it by extrusion molding to form a profile with the following cross-section: an outer side (101) and an inner side (102) extending vertically along the profile, an upper top edge (103) and a lower top edge (104) connecting the outer side (101) and the inner side (102), an extension edge (105) at the upper end of the outer side (101), and a bottom edge (107) extending horizontally from the middle of the inner side (102). b. Perform intermittent local cutting on the profile to form intermittently distributed retained sections (a) and cutting sections (b), and cut along the middle of the retained section (a) so that each cut profile has four cutting sections (b). c. The profile after step b is bent along the cutting section (b) using a bending mechanism to form a rounded rectangular structure. d. Fix the remaining half sections (a) at both ends of the profile after step c using a connector (200) to obtain the aluminum material for solar photovoltaic support; The bending mechanism includes a frame (10), on which a main pressure roller (11) and two side pressure rollers (12) symmetrically arranged on both sides of the main pressure roller (11) are mounted. The main pressure roller (11) and the two side pressure rollers (12) are all fixedly connected to a moving mechanism that drives the three to reciprocate linearly. The angle (α) between the moving trajectory of the two side pressure rollers (12) and the moving trajectory of the main pressure roller (11) is an acute angle. The main pressure roller (11) and the side pressure rollers (12) can both rotate around the center and can achieve independent forward and reverse rotation. A guide block (14) is also provided on the frame (10). The guide block (14) is located on the frame (10) outside the near end of the main pressure roller (11) and the two side pressure rollers (12). The side of the guide block (14) facing the main pressure roller (11) is an arc guide surface (141).

2. The method for manufacturing an aluminum material for solar photovoltaic support according to claim 1, characterized in that: The portion cut off by the cutting segment (b) is the bottom edge (107), which is an isosceles trapezoid. The edges of the bottom edges (107) on both sides of the cutting segment (b) abut against each other after step c.

3. The method for manufacturing an aluminum material for solar photovoltaic support according to claim 1, characterized in that: The cutting section (b) is a cut (300) that cuts laterally along the bottom edge (107). The bottom edges (107) on both sides of the cut (300) are staggered and stacked after step c.

4. The method for manufacturing an aluminum material for solar photovoltaic support according to claim 3, characterized in that: The cut (300) extends to the inner side (102) and cuts it to form a slot (500) that facilitates bending.

5. A method for manufacturing an aluminum material for solar photovoltaic support according to any one of claims 1-4, characterized in that: The contact surfaces of the side pressure roller (12), the main pressure roller (11) and the aluminum material are located at the inner side (102) at the lower end of the bottom edge (107), and the height of the arc guide surface (141) is higher than the outer side (101).

6. A method for manufacturing an aluminum material for solar photovoltaic support according to any one of claims 1-4, characterized in that: The contact surface between the side pressure roller (12) and the aluminum material is located at the inner side (102) at the lower end of the bottom edge (107), the contact surface between the main pressure roller (11) and the aluminum material is located at the inner side (102) at the upper end of the bottom edge (107), and the height of the arc guide surface (141) is higher than that of the outer side (101).

7. A method for manufacturing an aluminum material for solar photovoltaic support according to any one of claims 1-4, characterized in that: The angle (α) between the moving trajectory of the two side pressure rollers (12) and the moving trajectory of the main pressure roller (11) is 40-45 degrees.

Images