Photovoltaic module frame manufacturing method

Abstract

The application discloses a kind of photovoltaic module frame manufacturing method, including the steps of preparing bending steel plate, providing guarantee type steel step and the step of combining bending steel plate with standard steel plate.The bending steel plate is formed to accommodate photovoltaic laminated component installation groove, and the bending steel plate is riveted together with the standard steel plate, to enhance the strength of the bending steel plate.Compared with the existing aluminum extrusion photovoltaic module frame preparation method, the method of the application reduces the frame cost by using standard steel and steel plate.

Description

[0001] This application is a divisional application. The original application has the application number 2023103032840, the application date is March 24, 2023, and the title is "A frame for photovoltaic modules and a photovoltaic module". Technical Field

[0002] This invention relates to the field of photovoltaic power generation technology, and more specifically to a frame for photovoltaic modules and a photovoltaic module. Background Technology

[0003] With the increasing depletion of traditional fossil fuels globally, solar energy has received widespread attention and research due to its advantages such as being pollution-free, easy to collect, and having enormous capacity. After decades of development, solar energy-related components have been developed and put into the market, bringing convenience to people's work and life, while also greatly reducing the consumption of fossil fuels.

[0004] As one of the main components for converting solar energy into electrical energy, photovoltaic modules are widely used in the construction industry, which not only significantly reduces building energy consumption but also achieves remarkable energy-saving and environmental protection effects.

[0005] Photovoltaic modules include laminates and frames. The frames are used to encapsulate and protect the laminates on all four sides. The frames are fixed to the photovoltaic brackets of the photovoltaic power station to form a complete photovoltaic power generation system.

[0006] Currently, frames are mainly made of aluminum alloy profiles, but aluminum alloy profiles are expensive, and large-sized aluminum frames have poor mechanical load-bearing capacity, making it difficult to meet the requirements of protective laminates. Some frames are also made of steel, but steel frames are manufactured through multiple sheet metal bending processes and welding, resulting in a complex structure and high production costs. Summary of the Invention

[0007] To address at least one technical problem of the prior art, the present invention provides a frame for a photovoltaic module and a photovoltaic module.

[0008] To achieve the aforementioned objectives, the technical solution adopted by this invention is: a frame for a photovoltaic module, comprising: a standard steel profile, including a first wall and a second wall adjacent to the first wall; and

[0009] A bent steel plate, comprising: a support section, an outer section and an inner section bent at both edges of the support section toward opposite sides of the support section, and a top section bent from the edge of the outer section toward one side and opposite to the support section, wherein the support section, the outer section and the top section form an opening in the mounting groove.

[0010] The support segment is supported by the first wall, and the inner segment is attached to the surface of the second wall and riveted to the second wall.

[0011] In some embodiments, the standard steel section is a standard square steel tube or a C-shaped steel section.

[0012] In some embodiments, the inner side segment has a plurality of first riveting holes spaced apart along its length, and the second wall has a plurality of second riveting holes spaced apart in a square pattern along its length. The second riveting holes are concentric with the first riveting holes and are arranged in a one-to-one correspondence. The inner side segment and the second wall are connected by pop rivets passing through the first riveting holes and the second riveting holes.

[0013] In some embodiments, a plurality of sockets are arranged at intervals along the length of the standard steel on the second wall, and a plurality of inserts corresponding to the sockets and integrally connected to the inner section and bent into the standard steel through the corresponding sockets are arranged at intervals along the length of the bent steel plate on the inner section.

[0014] In some embodiments, a region is formed on the inner segment with one side connected to the inner segment and the other three sides cut off, and the region is bent outward with its connecting side as the center to form the insert.

[0015] In some embodiments, the insertion port is located at the edge where the second wall connects to the first wall, and the insertion port is an elongated strip extending along the length direction of the second wall; the side of the insert connected to the inner section is located at the intersection of the inner section and the support section, and extends along the length direction of the inner section.

[0016] In some embodiments, the bent steel plate further includes a bottom section that bends from the edge of the inner section toward the direction away from the second wall. The lower surface of the bottom section is flush with the lower surface of the standard steel section. The bottom section has a plurality of mounting holes spaced apart along its length. The frame is fixed to a fixture by means of pressure blocks or bolts passing through the mounting holes.

[0017] In some embodiments, the wall thickness of the standard steel section is 0.5mm to 2.5mm; the wall thickness of the bent steel plate is 0.5mm to 2.5mm.

[0018] In some embodiments, the frame is formed within the mounting groove with an anti-overflow structure to prevent adhesive from overflowing onto the front side of the laminate; the anti-overflow structure is a constriction formed at the opening of the mounting groove, or at least an overflow groove formed in the recess of the inner wall of the top section.

[0019] A photovoltaic module includes a rectangular frame formed by connecting four of the above-mentioned frame members end to end with corner brackets and a laminate embedded in the rectangular frame, wherein the edge of the laminate is encapsulated in the mounting groove of the frame member.

[0020] Due to the application of the above technical solution, the present invention has the following advantages compared with the prior art:

[0021] (1) The frame of this patent is made of steel, which is easy to obtain and has low material cost;

[0022] (2) The frame of this patent is made of standard steel and bent steel plate riveted together. The processing technology is simple, the processing time is short, and the manufacturing cost is low.

[0023] (3) Standard steel profiles and steel plates with different wall thicknesses can be selected according to different loads and application scenarios, so that the frame can adapt to different load requirements and installation scenarios;

[0024] (4) The frame support is connected by corner brackets, and the corner brackets are riveted to the standard steel, which makes the connection firm and the stability high;

[0025] (5) Standard steel sections and bent steel plates are connected by blind rivets. The connection method is simple and the process is conventional. Attached Figure Description

[0026] Figure 1 An exploded view of the frame components is shown in one embodiment of the present invention;

[0027] Figure 2 A side view of the border is shown in one embodiment of the present invention;

[0028] Figure 3 An exploded view of the frame components is shown in another embodiment of the present invention;

[0029] Figure 4 A cross-sectional view of the border is shown in one embodiment of the present invention;

[0030] Figure 5 A cross-sectional view of the border is shown in another embodiment of the present invention;

[0031] Figure 6 This shows a schematic diagram of the connection between the standard steel profile and the angle bracket in one embodiment of the present invention;

[0032] Figure 7 A schematic diagram of the structure of a photovoltaic module according to one embodiment of the present invention is shown;

[0033] Figure 8 A cross-sectional view of a photovoltaic module according to one embodiment of the present invention is shown.

[0034] Symbol explanation:

[0035] Laminate A;

[0036] Frame B; Bent steel plate 1; Mounting groove 10; Narrowing 100; Glue overflow groove 101; Top section 11; First arc section 110; Outer section 12; Support section 13; Second arc section 130; Inner section 14; Insert 140; First riveting hole 141; Bottom section 15; Standard steel 2; First wall 21; Second wall 22; Insert 220; Second riveting hole 221; Pressing point 222; Blind rivet 3; Corner bracket 4; Limiting step 40. Detailed Implementation

[0037] To better understand the above-mentioned objectives, features, and advantages of the present invention, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. These drawings are simplified schematic diagrams, which only illustrate the basic structure of the present invention in a schematic manner. Therefore, they only show the components related to the present invention. It should be noted that, unless otherwise specified, the embodiments and features in the embodiments of this application can be combined with each other.

[0038] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein. Therefore, the scope of protection of the invention is not limited to the specific embodiments disclosed below.

[0039] Reference Figure 1 and Figure 2 A frame B for a photovoltaic module is provided, comprising a standard steel profile 2 and a bent steel plate 1 riveted to the standard steel profile 2. The standard steel profile 2 includes a first wall 21 and a second wall 22 adjacent to the first wall 21. The bent steel plate 1 includes a support section 13, an outer section 12 and an inner section 14 bent at the two edges of the support section 13 toward opposite sides of the support section 13, and a top section 11 bent from the edge of the outer section 12 toward one side and opposite to the support section 13. The support section 13, the outer section 12 and the top section 11 form an open mounting groove 10. The support section 13 is supported by the first wall 21, and the inner section 14 is attached to the surface of the second wall 22 and riveted to the inner section 14.

[0040] Among them, the bent steel plate 1 is made by bending a steel plate of a certain thickness. The standard steel 2 can be made of standard steel square tube or C-shaped steel. Both the bent steel plate 1 and the standard steel 2 are easy to obtain and have low material costs.

[0041] The forming process of frame B is roughly as follows: First, take a steel plate and bend it to form a bent steel plate 1 with mounting groove 10. Then, take a standard steel section 2 of the same length as the bent steel plate 1. Align the two ends of the standard steel section 2 with the two ends of the bent steel plate 1 and support the standard steel section 2 under the support section 13 of the bent steel plate 1. Finally, fix the second wall 22 of the standard steel section 2 to the inner section 14 of the bent steel plate 1 by riveting to form a frame B that can limit and support one edge of the laminate. Connect the four frames B end to end with corner brackets 4 to form a rectangular frame.

[0042] Reference Figure 3 In some embodiments, the inner section 14 has a plurality of first riveting holes 141 spaced apart along its length, and the second wall 22 has a plurality of second riveting holes 221 spaced apart in a square pattern along its length. The second riveting holes 221 are concentric with and correspond one-to-one with the first riveting holes 141. The inner section 14 and the second wall 22 are connected by blind rivets 3 passing through the first riveting holes 141 and the second riveting holes 221. To facilitate the installation of the blind rivets 3, the first riveting holes 141 are located in the middle of the inner section 14, and the second riveting holes 221 are located in the middle of the second wall 22.

[0043] Reference Figure 3 and Figure 4 In some embodiments, a plurality of slots 220 are arranged at intervals along the length of the standard steel profile 2 on the second wall 22, and a plurality of inserts 140 corresponding to the slots 220 and integrally connected to the inner section 14 and bent into the standard steel profile 2 through the corresponding slots 220 are arranged at intervals along the length of the bent steel plate 1 on the inner section 14. During the assembly of the frame B, after aligning the two ends of the standard steel profile 2 with the two ends of the bent steel plate 1, the inserts 140 are inserted into the slots 220, and then the second wall 22 of the standard steel profile 2 and the inner section 14 of the bent steel plate 1 are fixed together by riveting. Therefore, by setting the slots 220 and the inserts 140, the initial connection and mutual positioning of the standard steel profile 2 and the bent steel plate 1 can be achieved, which facilitates the riveting of the standard steel profile 2 and the bent steel plate 1.

[0044] In some embodiments, a region is formed on the inner section 14 with one side connected to the inner section 14 and the other three sides cut off. This region is then bent outward from its connecting side to form an insert 140. To facilitate the bending of this region outward from its connecting side to form the insert 140, there is a certain gap between the three cut edges of this region and the cut portions of the inner section 14 opposite to the three cut edges.

[0045] In some embodiments, the socket 220 is located at the edge where the second wall 22 connects to the first wall 21, and the socket 220 is an elongated strip extending along the length direction of the second wall 22; the side of the insert 140 that connects to the inner section 14 is located at the intersection of the inner section 14 and the support section 13, and extends along the length direction of the inner section 14.

[0046] In some embodiments, the socket 220 and the second riveting hole 221 are staggered and alternately distributed on the second wall 22; the insert 140 and the first riveting hole 141 are staggered and alternately distributed on the inner section 14. This arrangement facilitates the forming of the socket 220, the riveting hole (221, 141) and the insert 140, as well as the riveting of the standard steel 2 and the bent steel plate 1. It also reduces the impact of the socket 220, the riveting hole (221, 141) and the insert 140 on the strength and load-bearing capacity of the frame (B).

[0047] In some embodiments, the standard steel section 2 and the bent steel plate 1 can be selected with different wall thicknesses according to different loads and installation scenarios. The wall thickness of the standard steel section 2 is 0.5mm to 2.5mm, and the wall thickness of the bent steel plate 1 is 0.5mm to 2.5mm, both of which conform to the international standard steel standards.

[0048] Reference Figure 2 and Figure 3 The top surface segment 11 can be configured to partially obscure the support segment 13, or it can be configured to completely or nearly completely obscure the support segment 13. The top surface segment 11 and the support segment 13 can be planar or non-planar.

[0049] In some embodiments, the frame B has an anti-overflow structure formed in the mounting groove 10 to prevent adhesive from overflowing onto the front side of the laminate A. The anti-overflow structure is a constriction 100 formed at the opening of the mounting groove 10 or at least an overflow groove 101 formed in the recess of the inner wall of the top section 11.

[0050] Reference Figure 4The constriction 100 is formed by bending a portion of the top surface section 11 toward the support section 13. To further enhance the anti-overflow capability of the constriction 100, the opening of the mounting groove 10 is constructed in the shape of the constriction 100. The width of the constriction 100 is smaller than the internal width of the mounting groove 10. During photovoltaic module mounting, the constriction 100 structure can prevent adhesive from overflowing from the mounting groove 10. For example, at least the portion of the top surface section 11 located at the opening of the mounting groove 10 is bent toward the opening direction (or the support section 13), making the opening width of the mounting groove 10 smaller than the internal thickness of the mounting groove 10, thus forming the aforementioned constriction 100. This at least suppresses adhesive overflow from the front side of the photovoltaic laminate. Preferably, the portions of the top surface section 11 and the support section 13 located at the opening of the mounting groove 10 are bent toward each other to form the aforementioned constriction 100 with a narrowed opening. This reduces adhesive overflow on both sides of the photovoltaic laminate.

[0051] The anti-overflow adhesive structure can also be an adhesive overflow channel 101. During the photovoltaic laminate mounting process, when the adhesive in the mounting groove 10 is squeezed and partially flows into the opening of the mounting groove 10, the adhesive overflow channel 101 contains part of the adhesive, preventing the adhesive from further overflowing outside the mounting groove 10. In one embodiment, referring to... Figure 5 The glue overflow groove 101 is formed only on the inner wall of the top section 11 and is recessed, which reduces glue overflow on the front. In other embodiments, in addition to the top section 11 having the glue overflow groove 101, a recessed glue overflow groove 101 can also be formed on the support section 13. The glue overflow groove 101 is a structure that is recessed relative to a reference, and its specific shape is not limited to that shown in the drawings.

[0052] In some embodiments, the bent steel plate 1 further includes a bottom section 15 that bends from the edge of the inner section 14 toward the direction away from the second wall 22. The lower surface of the bottom section 15 is flush with the lower surface of the standard steel section 2. The bottom section 15 has multiple mounting holes spaced apart along its length. The frame B is fixed to a bracket, roof, or wall by means of pressure blocks or bolts passing through the mounting holes. Specifically, a set of opposing long frames forming a rectangular frame is provided with a bottom section 15. The other set of opposing short frames forming the rectangular frame may or may not be provided with a bottom section 15. Whether the short frames are provided with a bottom section 15 depends on different loads and application scenarios. When the frame load is large or needs to be firmly installed on a fixed object, the short frames are provided with a bottom section 15.

[0053] Reference Figure 6 In some embodiments, two adjacent borders B of the rectangular frame are connected by corner brackets 4, which can be made of aluminum alloy or steel. The corner bracket 4 consists of two vertically connected blocks, which are respectively riveted to the ends of two adjacent standard steel profiles 2.

[0054] In some embodiments, the standard steel profile 2 has multiple rivet points 222 protruding towards the connecting blocks assembled within the standard steel profile 2 at both ends of the second wall 22. Preferably, the second wall 22 has four rivet points 222 at each end, and the four rivet points 222 are arranged in a rectangular pattern on the rectangular second wall 22.

[0055] In some embodiments, the connecting block is provided with multiple limiting steps 40 on the end face facing the second wall 22. The limiting steps 40 cooperate with the rivet points 222. Through the cooperation of the limiting steps 40 and the rivet points 222, the stability of the connection between the corner bracket 4 and the standard steel 2 can be further enhanced, making the connection more secure.

[0056] Reference Figure 7 and Figure 8 According to another aspect of this disclosure, a photovoltaic module is provided, including a rectangular frame formed by four frame Bs connected end to end by corner brackets 4 and a laminate A embedded in the rectangular frame. The edge of the laminate A is encapsulated in the mounting groove 10 of the frame B and is bonded to the bent steel plate 1 by silicone or structural adhesive.

[0057] Laminate A is used to receive sunlight and convert solar energy into electrical energy. Laminate A can be a crystalline silicon power generation panel made by laminating crystalline silicon solar cells, glass, adhesive, etc., or it can be a perovskite power generation panel formed by coating perovskite power generation materials onto a glass substrate.

[0058] The frame and photovoltaic module disclosed herein have the following advantages:

[0059] (1) The frame of this patent is made of steel, which is easy to obtain and has low material cost;

[0060] (2) The frame of this patent is made of standard steel and bent steel plate riveted together. The processing technology is simple, the processing time is short, and the manufacturing cost is low.

[0061] (3) Standard steel profiles and steel plates with different wall thicknesses can be selected according to different loads and application scenarios, so that the frame can adapt to different load requirements and installation scenarios;

[0062] (4) The frame support is connected by corner brackets, and the corner brackets are riveted to the standard steel, which makes the connection firm and the stability high;

[0063] (5) Standard steel sections and bent steel plates are connected by blind rivets. The connection method is simple and the process is conventional.

[0064] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections or electrical connections; they can refer to direct connections or indirect connections through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0065] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to the above embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A method for manufacturing a photovoltaic module frame, characterized in that, include: The steps for preparing a bent steel plate include providing a steel plate comprising a support section, bending the steel plate from both edges of the support section toward opposite sides of the support section to form an outer section and an inner section respectively, bending the steel plate from the edge of the outer section toward one side of the outer section to form a top section opposite to the support section, forming a region on the inner section with one side connected to the inner section and the other three sides cut off, bending the region outward with its connecting edge as the center to form an insert, and forming a plurality of first riveting holes spaced apart along its length extension direction on the inner section; The step of providing standard steel profiles, wherein the standard steel profiles include a first wall and a second wall adjacent to the first wall, and a plurality of insertion slots and a plurality of second riveting holes are formed on the second wall at intervals along its length extension direction; The steps of combining the bent steel plate with the standard steel section are as follows: support the standard steel section under the support section, insert the insert into the socket, and fix the standard steel section and the inner section together by riveting. The standard steel used in the method is standard square steel tube; In the riveting and fixing method, blind rivets are used to rivet the standard steel section to the inner section; The insertion port is located at the edge where the second wall connects to the first wall, and the insertion port is an elongated strip extending along the length direction of the second wall; the side of the insert that connects to the inner section is located at the intersection of the inner section and the support section, and extends along the length direction of the inner section.

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