Photovoltaic module frame and preparation method thereof

Abstract

The invention provides a photovoltaic module frame and a preparation method thereof. The preparation method of the photovoltaic module frame comprises the following steps: leading out glass fibers from a spool, and arranging the glass fibers with consistent density through a yarn arrangement frame; placing the uniformly arranged glass fibers in a pre-prepared adhesive to dip the glass fibers so as to form an integrated structure; laying a felt on the integrated structure to form a frame main body material; the frame main body material is laid on the surface of a reinforcing piece prepared in advance in a surrounding mode through a forming mold, so that a composite profile is formed; and curing the composite profile through a heating curing device to enhance the transverse strength of the photovoltaic frame and the assembly thereof, thereby avoiding tearing of the bottom edge of the assembly when the bottom edge of the assembly is subjected to a wind load.

Description

Technical Field

[0001] The present invention relates to the technical field of solar power generation, and particularly to a photovoltaic module frame and a preparation method thereof. Background Art

[0002] At present, the mainstream composite material frames on the market are made of composite materials composed of glass fiber and resin. Due to the anisotropy of the mechanical properties of this material, its mechanical properties in the direction of glass fiber extension are much stronger than those in the transverse direction.

[0003] When the composite material is used as a photovoltaic frame, if the cross-section direction of the frame is consistent with the glass fiber direction, the transverse direction is the low-performance direction. However, during the service of the frame, screws are usually locked at the bottom of the module. Therefore, when it is subjected to wind load, it is prone to tearing.

[0004] In order to overcome the above-mentioned defects existing in the prior art, there is an urgent need for a photovoltaic module frame technology in this field to strengthen the transverse strength of the photovoltaic frame and its components, so as to avoid tearing when the bottom of the module is subjected to wind load. Summary of the Invention

[0005] The following gives a brief overview of one or more aspects to provide a basic understanding of these aspects. This overview is not an exhaustive survey of all contemplated aspects, and is neither intended to identify key or decisive elements of all aspects nor to define the scope of any or all aspects. Its sole purpose is to present some concepts of one or more aspects in a simplified form as a prelude to a more detailed description to follow.

[0006] In order to overcome the above-mentioned defects existing in the prior art, the present invention provides a photovoltaic module frame and a preparation method thereof, which are used to strengthen the transverse strength of the photovoltaic frame and its components, so as to avoid tearing when the bottom of the module is subjected to wind load.

[0007] Specifically, the preparation method of the photovoltaic module frame provided by the first aspect of the present invention includes the following steps: leading out glass fiber from a yarn bobbin and arranging it in a uniform density via a yarn arranging rack; placing the uniformly arranged glass fiber in a pre-prepared adhesive to impregnate the glass fiber to form an integral structure; laying a felt on the integral structure to form a main frame material; laying the main frame material around a pre-prepared reinforcing member via a forming mold to form a composite profile; and curing the composite profile via a heating and curing device.

[0008] Further, in some embodiments of the present invention, the preparation method further includes: stretching the cured composite profile; and cutting the composite profile according to a preset length interval.

[0009] Further, in some embodiments of the present invention, the preparation method further includes pre-treating the reinforcement member, and the steps of the pre-treatment include: pulling out a steel coil via an unfolding device to form a continuous steel strip; processing the steel strip into a required cross-sectional shape by gradually bending to form a cold-formed steel; and cleaning the surface of the cold-formed steel.

[0010] Further, in some embodiments of the present invention, the impregnation of the glass fiber is carried out using polyether polyol and toluene diisocyanate, the impregnation temperature is 10 - 60 °C, the impregnation time is 5 - 60 s, the curing temperature of the composite profile is 150 - 230 °C, and the time is 5 - 60 s.

[0011] In addition, the frame of the photovoltaic module provided in the second aspect of the present invention includes: a frame body, which is composed of glass fiber, felt and an adhesive, wherein the glass fiber is bonded into an integral structure via the adhesive, and the felt is laid on the integral structure; and a reinforcement member, which is located inside the frame body and perpendicular to the extending direction of the glass fiber, and is used to cooperate with the frame body to form a composite profile to enhance the lateral strength of the frame body.

[0012] Further, in some embodiments of the present invention, the composite profile further includes an ultraviolet-resistant coating, which is coated on the outer layer of the felt via a matrix resin and is used to slow down the aging of the frame body material.

[0013] Further, in some embodiments of the present invention, the adhesive is polyurethane, and the proportion of polyurethane in the composite profile is 2.00 - 2.10 g / cm 3 .

[0014] Further, in some embodiments of the present invention, the hardness of the composite profile is greater than 50 Hba, the longitudinal tensile strength is 1000 - 1300 Mpa, the transverse tensile strength is 100 - 300 Mpa, the longitudinal bending strength is 1200 - 1700 Mpa, the longitudinal bending modulus is not less than 40 Gpa, the volume resistivity is greater than 10 14 Ω·m, the shear strength is 40 - 70 Mpa, and the heat distortion temperature is 240 - 250 °C.

[0015] Further, in some embodiments of the present invention, the frame body includes a bottom edge and multiple support rods, and the reinforcement member is located inside the bottom edge and at least one of the support rods.

[0016] Further, in some embodiments of the present invention, the material of the reinforcement member is one of coated steel, stainless steel, weathering steel and high-strength aluminum alloy. Description of the Drawings

[0017] After reading the detailed description of the embodiments of the present disclosure in conjunction with the following drawings, the above features and advantages of the present invention can be better understood. In the drawings, the components are not necessarily drawn to scale, and components with similar relevant characteristics or features may have the same or similar reference numerals.

[0018] Figure 1 The structural schematic diagram of the frame of a photovoltaic module provided according to some embodiments of the present invention is shown.

[0019] Figures 2A to 2B The structural schematic diagram of the reinforcement member located inside two support rods provided according to some embodiments of the present invention is shown.

[0020] Figures 3A to 3B The structural schematic diagram of the reinforcement member located inside the outer support rod provided according to some embodiments of the present invention is shown.

[0021] Figures 4A to 4B The structural schematic diagram of the reinforcement member located inside the inner support rod provided according to some embodiments of the present invention is shown.

[0022] Figure 5 The flow schematic diagram of the preparation method of the frame of a photovoltaic module provided according to some embodiments of the present invention is shown.

[0023] Reference numerals:

[0024] 10 Frame body

[0025] 101 Bottom edge

[0026] 102 Support rod

[0027] 20 Reinforcement member

[0028] 301 Yarn bobbin

[0029] 302 Yarn arranging frame

[0030] 303 Impregnation tank

[0031] 401 Steel coil

[0032] 402 Steel strip

[0033] 403 Cold bending roller

[0034] 404 Cold formed section steel

[0035] 405 Section steel surface treatment equipment

[0036] 406 Forming die

[0037] 407 Heating and curing device

[0038] 408 Pultrusion device

[0039] 409 Composite profile

[0040] 410 Cutting machine

[0041] 411 Sectional profile Detailed implementation manners

[0042] The following specific embodiments illustrate the implementation manners of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. Although the description of the present invention will be introduced in conjunction with the preferred embodiments, this does not mean that the features of this invention are limited to this implementation manner. On the contrary, the purpose of introducing the invention in conjunction with the implementation manner is to cover other alternatives or modifications that may be extended based on the claims of the present invention. In order to provide a deep understanding of the present invention, many specific details will be included in the following description. The present invention can also be implemented without using these details. In addition, in order to avoid confusing or obscuring the key points of the present invention, some specific details will be omitted in the description.

[0043] In the description of the present invention, it should be noted that unless otherwise clearly specified and defined, the terms "installation", "connection", and "coupling" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be directly connected or indirectly connected through an intermediate medium, and it can be the communication inside two components. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific situations.

[0044] In addition, the "upper", "lower", "left", "right", "top", "bottom", "horizontal", and "vertical" used in the following description should be understood as the orientations shown in this section and the related drawings. This relative term is only for convenience of description and does not represent that the device described needs to be manufactured or operated in a specific orientation. Therefore, it should not be construed as a limitation to the present invention.

[0045] It can be understood that although the terms "first", "second", "third", etc. can be used here to describe various components, regions, layers, and / or parts, these components, regions, layers, and / or parts should not be limited by these terms, and these terms are only used to distinguish different components, regions, layers, and / or parts. Therefore, the first component, region, layer, and / or part discussed below can be referred to as the second component, region, layer, and / or part without departing from some embodiments of the present invention.

[0046] Currently, the mainstream composite material frames on the market are made of composite materials composed of glass fiber and resin. Due to the anisotropy of the mechanical properties of this material, its mechanical properties in the direction of glass fiber extension are much stronger than those in the transverse direction.

[0047] When the composite material is used as a photovoltaic frame, if the cross-section direction of the frame is consistent with the direction of the glass fiber, the horizontal direction is the low-performance direction. However, during the service of the frame, screws are usually locked to the bottom edge of the component. Therefore, when it is subjected to wind load, it is prone to tearing.

[0048] In order to overcome the above-mentioned defects existing in the prior art, there is an urgent need in the art for a photovoltaic module frame technology to enhance the horizontal strength of the photovoltaic frame and its components, thereby avoiding tearing when the bottom edge of the component is subjected to wind load.

[0049] In some non-limiting embodiments, the frame of the photovoltaic module provided in the second aspect of the present invention is prepared by the method for preparing a photovoltaic module frame provided in the first aspect of the present invention.

[0050] Specifically, please refer to Figure 1 , Figure 1 , which shows a schematic structural diagram of a frame of a photovoltaic module provided according to some embodiments of the present invention.

[0051] As Figure 1 shown, the frame of the photovoltaic module includes a frame body 10 and a reinforcing member 20. The frame body 10 is composed of glass fiber, felt and an adhesive. The glass fiber is bonded into an integral structure by the adhesive, and the felt is laid on the integral structure. The reinforcing member 20 is located inside the frame body 10 and perpendicular to the extending direction of the glass fiber, and is used to cooperate with the frame body 10 to form a composite profile 409 to enhance the horizontal strength of the frame body 10. Here, its horizontal tensile strength is increased by more than 300%.

[0052] Here, the overall bonding area of the cross-section of the reinforcing member 20, as an extension of the protruding area of the bottom edge 101, can make the reinforcing member 20 and the frame body 10 form a unified whole, further ensuring the tear resistance of the bottom edge 101.

[0053] In some embodiments, the frame body 10 includes a bottom edge 101 and a plurality of support rods 102, and the reinforcing member 20 is located inside the bottom edge 101 and at least one of the support rods 102.

[0054] Please refer to Figures 2A to 2B , Figures 3A to 3B and Figures 4A to 4B . Figures 2A to 2B shows a schematic structural diagram of the reinforcing member located inside two support rods provided according to some embodiments of the present invention. Figures 3A to 3B shows a schematic structural diagram of the reinforcing member located inside the outer support rod provided according to some embodiments of the present invention. Figures 4A to 4B shows a schematic structural diagram of the reinforcing member located inside the inner support rod provided according to some embodiments of the present invention.

[0055] As Figures 2A to 2B shown, the reinforcement member 20 is located inside two support rods 102, and the lengths of the reinforcement member 20 on both sides of the support rod 102 can be equal, or the outer side can be longer than the inner side. Those skilled in the art can understand that the structure where the inner side is longer than the outer side can also be adopted for the lengths of the reinforcement member 20 on both sides of the support rod 102.

[0056] As Figures 3A to 3B and Figures 4A to 4B shown, the reinforcement member 20 can be located inside any one of the support rods 102 to achieve the effect of preventing tearing.

[0057] Those skilled in the art can understand that the specific position and length of the reinforcement member 20 in the frame body 10, including but not limited to the specific structures shown in the above embodiments, can select the optimal solution according to comprehensive verification.

[0058] In addition, in some embodiments, the composite profile 409 further includes an anti-ultraviolet coating, which is coated on the outer layer of the felt via a matrix resin (such as: polyurethane) to slow down the aging of the material of the frame body 10 and further improve the mechanical strength of the frame body 10.

[0059] In some embodiments, the adhesive can be polyurethane, and the proportion of the polyurethane in the composite profile 409 is 2.00 - 2.10 g / cm 3 .

[0060] Furthermore, the hardness of the composite profile 409 is greater than 50Hba, the longitudinal tensile strength (Machine Direction, MD) is 1000 - 1300 Mpa, the transverse tensile strength (Transverse Direction, TD) is 100 - 300 Mpa, the longitudinal bending strength (Machine Direction, MD) is 1200 - 1700 Mpa, the longitudinal bending modulus (Machine Direction, MD) is not less than 40 Gpa, the volume resistivity is greater than 10 14 Ω·m, the shear strength is 40 - 70 Mpa, and the heat deflection temperature (Heat Deflection Temperature, HDT) is 240 - 250 °C.

[0061] In some embodiments, the material of the reinforcement member 20 can be one of coated steel, stainless steel, weathering steel, and high-strength aluminum alloy. Here, the coated steel can be galvanized aluminum-magnesium steel or galvanized steel.

[0062] The preparation method of the above-mentioned photovoltaic module frame will be described below in conjunction with some embodiments of the photovoltaic module frame. Those skilled in the art can understand that these embodiments of the preparation method of the photovoltaic module frame are only some non-limiting implementation manners provided by the present invention, aiming to clearly show the main concept of the present invention and provide some specific solutions convenient for the public to implement, rather than limiting all functions or all working modes of the photovoltaic module frame. Similarly, the photovoltaic module frame is also only some non-limiting implementation manners provided by the present invention, and does not limit the execution subject or execution order of each step in the preparation method of these photovoltaic module frames.

[0063] Please refer to Figure 5 , Figure 5 which shows a schematic flow chart of the preparation method of the photovoltaic module frame provided by some embodiments of the present invention.

[0064] As Figure 5 shown, the preparation method of the photovoltaic module frame can first draw the glass fiber from the yarn bobbin 301 and arrange it with a consistent density via the yarn arranging frame 302. The distribution of the glass fiber can be controlled by the configuration of the yarn arranging frame 302, so as to ensure the uniformity of the glass fiber distribution.

[0065] After that, the uniformly arranged glass fiber is placed in a pre-prepared adhesive to impregnate the glass fiber to form an integral structure. Then, a felt is laid on the integral structure to form the material of the frame body 10. The adhesive can be arranged in the impregnation tank 303 to impregnate the glass fiber. The adhesive can adopt polyether polyol and toluene diisocyanate (TDI), the impregnation temperature is 10 - 60 °C, and the impregnation time is 5 - 60 s.

[0066] After that, via the forming die 406, the frame body 10 material is laid around the pre-prepared reinforcement 20 to form a composite profile 409. The forming die 406 needs to ensure that the size and shape of the frame body 10 material after being combined with the cold-formed steel 404 meet the design requirements. Here, the frame body 10 material and the cold-formed steel 404 are combined into a whole.

[0067] After that, via the heating and curing device 407, the composite profile 409 is cured to reach the design strength and performance. The temperature for curing the composite profile 409 is 150 - 230 °C, and the time is 5 - 60 s.

[0068] After that, the cured composite profile 409 is stretched via the pultrusion device 408 to maintain a stable size. Here, the pultrusion process needs to avoid deformation and deviation at the same time.

[0069] Finally, the composite profile 409 is cut by a cutting machine 410 according to a preset length interval to obtain the required segmented profile 411.

[0070] In some embodiments, before forming the composite profile 409 by laying the frame body 10 material around the surface of the pre-prepared reinforcing member 20 via a forming die 406, the preparation equipment also needs to pre-treat the reinforcing member 20.

[0071] Specifically, the preparation equipment first pulls out a steel coil 401 via a deploying device to form a continuous steel strip 402. Then, the steel strip 402 is sent to the next process for cold bending forming via cold bending rollers 403. By gradually bending the steel strip 402, the steel strip 402 is processed into a required cross-sectional shape to form a cold-formed steel 404. After that, the surface of the cold-formed steel 404 is cleaned. Here, the surface of the cold-formed steel 404 is subjected to removing dirt, scale or other contaminants via a section steel surface treatment device 405. Common methods include decontamination, sanding, etc., to provide better adhesion for subsequent processes (such as impregnation and composite material preparation).

[0072] In summary, the present invention provides a photovoltaic module frame and a preparation method thereof, which are used to strengthen the lateral strength of the photovoltaic frame and its components, so as to avoid tearing when the bottom edge of the component is subjected to wind load.

[0073] Although the above methods are illustrated and described as a series of actions for simplicity of explanation, it should be understood and appreciated that these methods are not limited by the order of the actions, because according to one or more embodiments, some actions may occur in a different order and / or concurrently with other actions not illustrated and described herein but understood by those skilled in the art.

[0074] The foregoing description of the disclosure has been provided to enable any person skilled in the art to make or use the disclosure. Various modifications to the disclosure will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other variations without departing from the spirit or scope of the disclosure. Thus, the disclosure is not intended to be limited to the examples and designs described herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A method for preparing a photovoltaic module frame, characterized in that: The following steps are involved: Lead the glass fiber out from the yarn drum and arrange it with uniform density through the yarn arrangement frame; placing the uniformly arranged glass fibers in a pre-formulated adhesive to impregnate the glass fibers to form an integral structure; Laying felt on the integrated structure to form a frame main body material; The frame main body material is laid around the pre-prepared reinforcement surface through a forming mold to form a composite profile; as well as The composite profile is cured by a heating and curing device.

2. The preparation method according to claim 1, characterized in that Also includes: Stretching the cured composite profile; as well as The composite profile is cut according to the preset length spacing.

3. The preparation method according to claim 1, characterized in that: The reinforcement is also pre-processed, and the pre-processing steps include: The steel coil is pulled out through the unwinding device to form a continuous steel strip; Processing the steel strip into a desired cross-sectional shape by gradually bending to form a cold-formed steel; and The surface of the cold-bent steel is cleaned.

4. The preparation method according to claim 1, characterized in that: The glass fiber is impregnated with polyether polyol and toluene diisocyanate, the impregnation temperature is 10 to 60° C., and the impregnation time is 5 to 60 seconds. The temperature for curing the composite profile is 150-230° C., and the time is 5-60 seconds.

5. A frame of a photovoltaic module, characterized in that: include: The frame body is composed of glass fiber, felt and adhesive, wherein the glass fiber is bonded into an integrated structure by the adhesive, and the felt is laid on the integrated structure; as well as The reinforcing piece is located inside the frame body and perpendicular to the extending direction of the glass fiber, and is used to cooperate with the frame body to form a composite profile to improve the lateral strength of the frame body.

6. The frame according to claim 5, characterized in that: The composite profile also includes an anti-ultraviolet coating, which is coated on the outer layer of the felt via a matrix resin to slow down the aging of the frame main body material.

7. The frame according to claim 5, characterized in that: The adhesive is polyurethane, and the specific gravity of the polyurethane in the composite profile is 2.00-2.10 g / cm 3 .

8. The frame according to claim 7, characterized in that: The composite profile has a hardness greater than 50 Hba, a longitudinal tensile strength of 1000-1300 MPa, a transverse tensile strength of 100-300 MPa, a longitudinal bending strength of 1200-1700 MPa, a longitudinal bending modulus of not less than 40 Gpa, and a volume resistivity greater than 10 14 Ω·m, shear strength is 40~70Mpa, and heat deformation temperature is 240~250℃.

9. The frame according to claim 5, characterized in that: The frame body comprises a bottom edge and a plurality of support rods, and the reinforcement member is located inside the bottom edge and at least one of the support rods.

10. The frame according to claim 5, characterized in that: The reinforcement is made of one of coated steel, stainless steel, weathering steel and high-strength aluminum alloy.

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