Cavityless frame and photovoltaic module

Abstract

The application discloses a frame without cavity and a photovoltaic module. The frame without cavity comprises a frame body, an abutting piece and a limiting piece. The frame body comprises a bearing part, a supporting part, a mounting part and a reinforcing part. The bearing part and the mounting part are arranged at intervals. The supporting part is arranged between the bearing part and the mounting part and connected to the bearing part and the mounting part. The surface of the bearing part away from the supporting part forms a bearing surface. One end of the reinforcing part is connected to the bearing part and the other end is connected to the supporting part. The abutting piece is connected to the first end of the bearing part. The limiting piece is connected to the end of the abutting piece away from the bearing part. The limiting piece, the abutting piece and the bearing surface form a mounting groove for mounting a laminated part. The groove opening of the mounting groove is directed to the second end. The application can reduce the material cost.

Description

Technical Field

[0001] This invention relates to the field of photovoltaic technology, and in particular to a cavity-less frame and a photovoltaic module. Background Technology

[0002] Traditional photovoltaic (PV) module frames have a locking section (generally called the frame A-side) to secure the laminated components to the edge of the front panel. The frame A-side primarily prevents the PV laminates from detaching, and its thickness is greater than the front glass. After prolonged outdoor use, the frame A-side can cause dust and rain to accumulate on the front of the PV module, affecting its power generation. Furthermore, traditional aluminum frames consist of two long frames and two short frames, each with its own cavity. The long and short frames are connected by corner brackets inserted into these cavities. This traditional frame design relies on corner brackets and requires cavities, resulting in high material costs and hindering cost reduction and efficiency improvements. Summary of the Invention

[0003] Therefore, it is necessary to provide a cavity-free frame. The cavity-free frame of the present invention eliminates the cavity structure and can achieve connection without corner brackets, which can significantly reduce material costs while maintaining the normal load of the cavity-free frame, thus achieving the goal of cost reduction and efficiency improvement.

[0004] One embodiment of this application provides a cavity-free border.

[0005] A cavity-free frame includes a frame body, an abutment, and a limiting member. The frame body includes a load-bearing portion, a support portion, a mounting portion, and a reinforcing portion. The load-bearing portion and the mounting portion are spaced apart. The support portion is disposed between and connected to the load-bearing portion and the mounting portion. The surface of the load-bearing portion away from the support portion forms a load-bearing surface. One end of the reinforcing portion is connected to the load-bearing portion, and the other end is connected to the support portion. The abutment is connected to a first end. The limiting member is connected to the end of the abutment away from the load-bearing portion. The limiting member, the abutment, and the load-bearing surface together form a mounting groove for mounting a laminate. The opening of the mounting groove faces the second end.

[0006] In some embodiments, the distance between the position where the reinforcing part is connected to the bearing part and the position where the bearing part and the support part are connected is L1, and the width of the bearing part is D1, wherein L1≥1 / 4D1.

[0007] In some embodiments, L1 is 1 / 2D1~D1.

[0008] In some embodiments, the distance between the position where the reinforcing part is connected to the support part and the position where the bearing part and the support part are connected is L2, and the height of the support part is D2, wherein L2≤2 / 3D2.

[0009] In some embodiments, L2 is 1 / 3D2 to 2 / 3D2.

[0010] In some embodiments, the connection between the support portion and the load-bearing portion has a rounded transition.

[0011] In some embodiments, the connection between the support portion and the mounting portion has a rounded transition.

[0012] In some embodiments, the radius R1 of the fillet at the connection between the support and the bearing is between 0.25 and 2.

[0013] In some embodiments, the radius R2 of the fillet at the connection between the support and the mounting portion is between 0.25 and 2.

[0014] In some embodiments, the frame body further includes a thickened portion connected to the support portion, the thickened portion protruding from the surface of the support portion for connection of the reinforcing portion.

[0015] In some embodiments, the end face of the support portion is flush with the end face of the first end of the bearing portion and the end face of one end of the mounting portion; preferably, the abutment member is flush with the support portion.

[0016] In some embodiments, the frame body further includes a connecting engagement portion, one end of which is connected to the support portion, and the other end of which extends away from the support portion along the plane of the support portion, and the end is curled. The connecting engagement portion is used to realize the engagement connection between adjacent frame bodies and connecting buckles.

[0017] In some embodiments, the maximum distance H1 between the top surface of the limiting member and the bearing surface is not greater than the thickness H2 of the laminate, the minimum distance H3 between the limiting member and the bearing surface is not less than the thickness H4 of the back panel on the laminate, the bearing surface is used to support part of the back panel of the laminate, the abutment is used to abut the end face of the back panel of the laminate, the end face of the limiting member is used to abut the end face of the front panel of the laminate, and the surface of the limiting member facing the bearing surface is used to press against part of the back panel of the laminate.

[0018] An embodiment of this application also provides a photovoltaic module.

[0019] A photovoltaic module includes a laminate and a cavity-free frame as described in any of the above embodiments. The laminate includes a back panel, a back adhesive film, a cell, a front adhesive film, and a front panel stacked sequentially. The laminate is encapsulated by the cavity-free frame. During encapsulation, the edges of the laminate are encapsulated within mounting grooves of the cavity-free frame.

[0020] In some embodiments, the edges of the back panel protrude beyond the edges of the front panel, the laminate is encapsulated by the cavity-free frame, a portion of the back panel of the laminate is located on the bearing surface, the end face of the back panel of the laminate can abut against the abutment, the end face of the front panel of the laminate abuts against the end face of the limiting member, and a portion of the back panel of the laminate abuts against the surface of the limiting member facing the bearing surface.

[0021] The aforementioned cavity-free frame can significantly reduce material costs while maintaining normal load-bearing capacity, achieving cost reduction and efficiency improvement. Specifically, in this application, the frame body is provided with a load-bearing part, a support part, a mounting part, and a reinforcing part. The edge of the laminate is installed in the mounting groove formed by the limiting part, the abutment part, and the load-bearing surface. The support part is located between and connects the load-bearing part and the mounting part. Compared with traditional technology, this application eliminates the cavity structure. This application directly uses the support part to connect the load-bearing part and the mounting part, reducing one side of the traditional frame. One end of the reinforcing part is connected to the load-bearing part, and the other end is connected to the support part to ensure the load-bearing capacity. Since this application eliminates the cavity, it does not require a corner bracket structure and can reduce the length of the mounting part and the height of the support part, significantly reducing material costs and achieving cost reduction and efficiency improvement. Furthermore, this application eliminates the cavity, thus enabling the foldable connection of adjacent cavity-free frames. Several cavity-free frames are connected in a movable manner, and after being folded as a whole, the cavity-free frames can be closed by using a special connector buckle.

[0022] Furthermore, the aforementioned cavity-less frame is configured as follows: the maximum distance H1 between the top surface of the limiting member and the bearing surface is not greater than the thickness H2 of the laminate, and the minimum distance H3 between the limiting member and the bearing surface is not less than the thickness H4 of the back panel on the laminate. In this case, the cavity-less frame can be adapted to laminates with a front panel width smaller than the back panel width. The abutting member abuts against the end face of the back panel of the laminate, and the end face of the limiting member abuts against the end face of the front panel of the laminate. The surface of the limiting member facing the bearing surface presses against part of the back panel of the laminate. This configuration ensures that the front panel of the laminate is not higher than the limiting member after encapsulation. When the photovoltaic module is in use, the junction between the front panel and the limiting member is not prone to dust or rain accumulation. Even if a small amount of dust accumulates, it can be quickly and thoroughly cleaned off the front panel by rainwater and will not remain on the front panel. This achieves the purpose of reducing dust accumulation and hot spots, while increasing the power generation of the photovoltaic module, reducing the frequency of module cleaning to a certain extent, and ensuring returns. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the embodiments of this application, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application, and those skilled in the art can obtain other drawings based on these drawings without creative effort.

[0024] To gain a more complete understanding of this application and its beneficial effects, the following description will be provided in conjunction with the accompanying drawings. In the following description, the same reference numerals denote the same parts.

[0025] Figure 1 This is a schematic diagram of a cavity-less frame according to an embodiment of the present invention;

[0026] Figure 2 This is a schematic diagram of a laminate structure according to an embodiment of the present invention;

[0027] Figure 3 This is a schematic diagram of the cavity-free frame and laminate packaging according to an embodiment of the present invention;

[0028] Figure 4 This is a schematic diagram of the cavity-free frame according to another embodiment of the present invention;

[0029] Figure 5 This is a schematic diagram of the cavity-less frame fitting according to another embodiment of the present invention.

[0030] Explanation of reference numerals in the attached figures

[0031] 10. Photovoltaic module; 100. Cavityless frame; 110. Frame body; 111. Bearing part; 112. Support part; 113. Mounting part; 114. Reinforcing part; 115. Thickened part; 101. Bearing surface; 102. Glue overflow groove; 120. Abutting part; 121. Abutting protrusion; 122. Extrusion protrusion; 130. Limiting part; 131. Limiting base; 140. Mounting groove; 150. Limiting protrusion; 151. Connecting part; 152. Bending part; 153. Auxiliary receiving area; 160. Connecting mating part; 170. Leaving area; 180. Pointed structure; 200. Laminated part; 201. Back panel; 202. Back adhesive film; 203. Cell; 204. Front adhesive film; 205. Front panel. Detailed Implementation

[0032] To make the above-mentioned objects, features, and advantages of the present invention more apparent and understandable, specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of the present invention. However, the present invention can be practiced in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0033] In the description of this invention, it should be understood that the terms "center," "longitudinal," "lateral," "length," "width," "thickness," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," "outer," "clockwise," "counterclockwise," "axial," "radial," and "circumferential" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0034] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0035] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0036] In the description of this invention, "several" means one or more, "multiple" means two or more, "greater than," "less than," and "exceeding" are understood to exclude the stated number, while "above," "below," and "within" are understood to include the stated number. The use of "first" and "second" in the description is merely for distinguishing technical features and should not be construed as indicating or implying relative importance, or implicitly indicating the number of indicated technical features, or implicitly indicating the order of the indicated technical features.

[0037] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0038] In this document, "optionally," "optionally," and "optional" mean that something is optional, that is, it is selected from either "with" or "without." If multiple "options" appear in a technical solution, unless otherwise specified and there are no contradictions or mutual constraints, each "option" is independent. In this application, descriptions such as "optionally contains" and "optionally includes" indicate "contains or does not contain."

[0039] In this application, "light-receiving surface or front side" and "backlighting surface or back side" are used only to distinguish the positions of the two opposing surfaces of the battery substrate. In actual operating conditions, the "light-receiving surface" is the surface of the battery substrate that primarily receives light, but the "backlighting surface" does not necessarily not receive light. In fact, due to the presence of diffuse reflection, the "backlighting surface" can also receive light in actual operating conditions.

[0040] In this application, when numerical intervals (i.e., numerical ranges) are mentioned, unless otherwise specified, the distribution of selectable numerical values ​​within the numerical interval is considered continuous, and includes the two endpoints of the numerical interval (i.e., the minimum and maximum values), as well as every numerical value between these two endpoints. Unless otherwise specified, when a numerical interval refers only to integers within that numerical interval, it includes the two endpoint integers of the numerical range, as well as every integer between the two endpoints, which is equivalent to directly listing every integer. When multiple numerical ranges are provided to describe features or characteristics, these numerical ranges can be merged. In other words, unless otherwise specified, the numerical ranges disclosed in this application should be understood to include any and all subranges included therein. The "numerical value" in the numerical interval can be any quantitative value, such as a number, percentage, ratio, etc. The term "numerical interval" can be broadly included to include percentage intervals, ratio intervals, proportion intervals, etc.

[0041] This application provides a cavity-less frame to solve at least one of the following technical problems existing in photovoltaic modules in the prior art: (1) After long-term outdoor use, photovoltaic modules will accumulate dust and rain, which will affect the normal power generation of photovoltaic modules; (2) The aluminum frame in the traditional technology consists of two long frames, two short frames and corner brackets. The frame consumes a lot of materials and the material cost is high, which is not conducive to cost reduction and efficiency improvement. The cavity-less frame will be described below with reference to the accompanying drawings.

[0042] The cavity-free border provided in this application embodiment is exemplary; please refer to [link / reference]. Figure 1 As shown, Figure 1 This is a schematic diagram of the cavity-less frame provided in an embodiment of this application. The cavity-less frame of this application can be used for laminate encapsulation to form photovoltaic modules.

[0043] To more clearly illustrate the structure of the cavity-less frame, the following description will be provided in conjunction with the accompanying drawings.

[0044] For example, please refer to Figure 1As shown, a cavityless frame 100 includes a frame body 110, an abutment 120, and a limiting member 130. The frame body 110 includes a support portion 111, a supporting portion 112, a mounting portion 113, and a reinforcing portion 114. The support portion 111 and the mounting portion 113 are spaced apart. The supporting portion 112 is disposed between and connects the support portion 111 and the mounting portion 113, and a bearing surface 101 is formed on the surface of the support portion 111 away from the supporting portion 112. One end of the reinforcing portion 114 is connected to the support portion 111, and the other end is connected to the supporting portion 112. The abutment 120 is connected to a first end of the support portion 111. The limiting member 130 is connected to the end of the abutment 120 away from the support portion 111. The limiting member 130, the abutting member 120 and the bearing surface 101 form a mounting groove 140 for mounting the laminate 200, and the opening of the mounting groove 140 faces the second end of the bearing portion 111.

[0045] The aforementioned cavity-less frame 100 can significantly reduce material costs while maintaining the normal load of the cavity-less frame 100, thereby achieving the goal of cost reduction and efficiency improvement. Specifically, in this application, the frame body 110 is provided with a bearing portion 111, a support portion 112, a mounting portion 113, and a reinforcing portion 114. The edge of the laminate 200 is installed in the mounting groove 140 formed by the limiting member 130, the abutment member 120, and the bearing surface 101. The support portion 112 is disposed between the bearing portion 111 and the mounting portion 113 and is connected to the bearing portion 111 and the mounting portion 113. Compared with the conventional technology, this application eliminates the cavity structure. In this application, the support portion 112 is directly used to connect the bearing portion 111 and the mounting portion 113, reducing one side of the conventional frame. The reinforcing portion 114 is connected to the bearing portion 111 at one end and to the support portion 112 at the other end to ensure the load is borne. Since this application eliminates the cavity, it does not require a corner bracket structure and can reduce the length of the mounting portion 113 and the height of the support portion 112, which greatly reduces material costs and achieves cost reduction and efficiency improvement.

[0046] In this application, the reinforcing part 114 connects the bearing part 111 and the supporting part 112 to form a triangular support, thereby strengthening the support effect and increasing the load-bearing capacity of the bearing part 111. See also Figure 1 As shown, in this application, after the support part 112 supports the bearing part 111, the end faces of the abutment part 120, the support part 112, the first end of the bearing part 111, and one end of the mounting part 113 can be flush in the vertical direction. Preferably, the length of the mounting part 113 is slightly larger than the length of the bearing part 111.

[0047] In this application, when encapsulating the laminate 200, multiple cavity-less frame 100s are used. Adjacent cavity-less frame 100s can be connected by hinges. When adjacent cavity-less frame 100s are connected by hinges, they can be folded together and snapped together at the last two cavity-less frame 100s to form a closed loop.

[0048] In some embodiments, the frame body 110, the abutment 120, and the limiting member 130 are connected as an integral structure.

[0049] In some embodiments, the support portion 112 is generally a plate-like structure and has no cavity structure.

[0050] In some embodiments, the distance between the position where the reinforcing part 114 is connected to the bearing part 111 and the connection position between the bearing part 111 and the support part 112 is L1, and the width of the bearing part 111 is D1, wherein L1 ≥ 1 / 4D1. It should be noted that the width D1 of the bearing part 111 refers to the distance along the direction from the edge position to the center position of the laminating part 200 after the cavity-less frame 100 and the laminate 200 are engaged.

[0051] In some embodiments, L1 is 1 / 2D1~D1. The position of the reinforcing part 114 connected to the supporting part 111, as limited as described above, ensures that the reinforcing part 114 effectively supports the supporting part 111.

[0052] In some embodiments, the distance between the position where the reinforcing part 114 is connected to the support part 112 and the connection position between the bearing part 111 and the support part 112 is L2. The height of the support part 112 is D2. Wherein, L2≤2 / 3D2. The height of the support part 112 is also the distance between the support part 112 and the mounting part 113.

[0053] In some embodiments, L2 is 1 / 3D2 to 2 / 3D2. The position of the reinforcing part 114 connected to the support part 112, as limited as described above, ensures that the reinforcing part 114 has an effective stress point on the support part 112, thereby improving the support strength of the reinforcing part 114 for the load-bearing part 111.

[0054] In some embodiments, the connection between the support portion 112 and the bearing portion 111 is a rounded transition.

[0055] In some embodiments, the connection between the support portion 112 and the mounting portion 113 is a rounded transition.

[0056] In some embodiments, the radius R1 of the fillet at the connection between the support portion 112 and the load-bearing portion 111 is between 0.25 and 2. This arrangement can increase the load capacity of the load-bearing portion 111.

[0057] In some embodiments, the radius R2 of the fillet at the connection between the support portion 112 and the mounting portion 113 is between 0.25 and 2. This arrangement increases the stability of the support portion 112 and increases the load on the load-bearing portion 111.

[0058] In some embodiments, the frame body 110 further includes a thickened portion 115. The thickened portion 115 is connected to the support portion 112 and protrudes from the surface of the support portion 112 for connection of the reinforcement portion 114. The thickened portion 115 can improve the support strength of the support portion 112 and increase the load of the entire cavityless frame 100.

[0059] In some embodiments, the thickened portion 115 has a certain length L3 on the support portion 112. Therefore, the length L3 of the thickened portion 115 is 1 / 3 to 1 / 2 of the height D2 of the support portion 112.

[0060] Preferably, see Figure 1 As shown, the thickened portion 115 is located at the middle position in the height direction of the support portion 112.

[0061] In some of these embodiments, see Figure 1 and 3 As shown, the connection position of one end of the reinforcing part 114 falls at the center of the supporting part 111, and can be finely adjusted according to the actual situation. The connection position of the other end of the reinforcing part 114 falls on the thickened part 115 of the supporting part 112. Preferably, the position of the other end of the reinforcing part 114 on the thickened part 115 can be arbitrarily selected. When the other end of the reinforcing part 114 is located on the thickened part 115, it can effectively support the supporting part 111.

[0062] In some embodiments, the support portion 112 is flush with the end face of the first end of the bearing portion 111 and the end face of one end of the mounting portion 113. Specifically, the support portion 112 is flush with the end face of the first end of the bearing portion 111 and the end face of the third end of the mounting portion 113; preferably, the abutment member 120 is flush with the support portion 112. See also Figure 1 As shown in the angle, the left side of the bearing portion 111 is the first end, and the right side is the second end. The left side of the mounting portion 113 is the third end, and the right side is the fourth end.

[0063] This application eliminates the cavity, thus enabling foldable connections between adjacent cavity-free frame 100s. Several cavity-free frame 100s are connected by a movable connection, such as a hinge connection, allowing adjacent cavity-free frame 100s to be folded together. After being folded as a single unit, the several cavity-free frame 100s can be sealed together using a dedicated connector snap-fit ​​to encapsulate the laminate 200.

[0064] In some of these embodiments, see Figure 4 As shown, Figure 4 This is a schematic diagram of a cavityless frame 100 according to another embodiment of the present invention. The frame body 110 further includes a connecting mating portion 160. One end of the connecting mating portion 160 is connected to the support portion 112, and the other end of the connecting mating portion 160 extends away from the support portion 112 along the plane of the support portion 112, and this end is curled. The connecting mating portion 160 is used to realize the mating connection between adjacent frame bodies 110 and connecting buckles. See also Figure 5 As shown, Figure 5 This is a schematic diagram of the fitting of the cavity-less frame 100 according to another embodiment of the present invention. After adjacent cavity-less frame 100s are mated, adjacent connecting fitting parts 160s come closer together. Since the outward-facing ends of the connecting fitting parts 160 are curled, there is a certain recessed clearance area 170 between adjacent connecting fitting parts 160s. This clearance area 170 is used for snap-fit ​​insertion to realize the snap-fit ​​of two adjacent connecting fitting parts 160s.

[0065] In some embodiments, when the connecting and mating part 160 is provided, the following adaptive structural adjustments can be made: See Figure 5 As shown, along the length of the frame body 110, the two end faces of the support portion 111 and the front and rear end faces of the support portion 112 are cut, so that the two end faces of the support portion 111 and the two end faces of the support portion 112 are respectively pointed structures 180, and the edges of the pointed structures 180 form a 90° angle. The length direction of the frame body 110 refers to the direction in which the length direction of the frame body 110 is parallel to the edge of the laminate 200 after encapsulation.

[0066] During cutting, the two end faces of the bearing portion 111 and the two end faces of the support portion 112 are cut, forming a pointed structure 180 with a 90° bend. After splicing the pointed structures 180 of adjacent cavity-free frame 100, the facing edges of the two pointed structures 180 fit together, and the outward edges of the two pointed structures 180 are flush. This arrangement provides space for the connecting mating portion 160 to curl. The lengths of the two edges of the pointed structure 180 can be set according to the width of the frame body 110 to achieve splicing alignment of adjacent frame bodies 110.

[0067] In some embodiments, the length of the connecting mating part 160 satisfies the following condition: after adjacent cavity-less frame edges 100 are mated, there is a certain gap between adjacent connecting mating parts 160, which is used for the snap-fit ​​part to engage.

[0068] In some embodiments, the connecting mating portion 160 can be prepared simultaneously during the end processing and cutting of the cavity-free frame 100, and during cutting, a portion of the position is retained to form the connecting mating portion 160 described above.

[0069] In some embodiments, the maximum distance H1 between the top surface of the limiting member 130 and the bearing surface 101 is not greater than the thickness H2 of the laminate 200, the width W1 of the limiting member 130 is less than the width W2 of the bearing surface 101, the minimum distance H3 between the limiting member 130 and the bearing surface 101 is not less than the thickness H4 of the back panel 201 on the laminate 200, the bearing surface 101 is used to support part of the back panel 201 of the laminate 200, the abutment member 120 is used to abut against the end face of the back panel 201 of the laminate 200, the end face of the limiting member 130 is used to abut against the end face of the front panel 205 of the laminate 200, and the surface of the limiting member 130 facing the bearing surface 101 is used to press against part of the back panel 201 of the laminate 200.

[0070] The cavity-less frame 100 described above is configured as follows: the maximum distance H1 between the top surface of the limiting member 130 and the bearing surface 101 is not greater than the thickness H2 of the laminate 200; the width W1 of the limiting member 130 is less than the width W2 of the bearing surface 101; and the minimum distance H3 between the limiting member 130 and the bearing surface 101 is not less than the thickness H4 of the back panel 201 on the laminate 200. In this configuration, the cavity-less frame 100 can fit laminates 200 where the width of the front panel 205 is less than the width of the back panel 201. (See [reference]). Figure 2 The laminate 200 shown has an abutment 120 abutting against the end face of the back panel 201 of the laminate 200, and a limiting member 130 abutting against the end face of the front panel 205 of the laminate 200. The surface of the limiting member 130 facing the bearing surface 101 presses against a portion of the back panel 201 of the laminate 200. This arrangement ensures that the front panel 205 of the laminate 200 is not higher than the limiting member 130 after encapsulation. When the photovoltaic module 10 is in use, the junction between the front panel 205 and the limiting member 130 is not prone to dust or rain accumulation. Even if a small amount of dust accumulates, it can be quickly and thoroughly cleaned off the front panel 205 by rainwater and will not remain on the front panel 205. This achieves the purpose of reducing dust accumulation and hot spots, while increasing the power generation of the photovoltaic module 10, reducing the frequency of module cleaning to a certain extent, and ensuring returns.

[0071] In some embodiments, the limiting member 130 is parallel to the bearing surface 101. Preferably, the outer surface of the limiting member 130 is a smooth surface or a sloping surface. When the outer surface of the limiting member 130 is a sloping surface, the height of the outer surface of the limiting member 130 from the bearing surface 101 gradually decreases from the side away from the abutment member 120 to the side closer to the abutment member 120, forming a sloping surface. This allows a small amount of dust accumulated on the front panel 205 to be washed away by rainwater, achieving the purpose of preventing dust accumulation.

[0072] In some embodiments, the maximum distance H1 between the top surface of the limiting member 130 and the bearing surface 101 is less than the thickness H2 of the laminate 200, and the distance between the end of the limiting member 130 away from the abutment 120 and the bearing surface 101 is greater than the distance between the end of the limiting member 130 closer to the abutment 120 and the bearing surface 101. It should be noted that, see [link to relevant documentation] Figure 1 As shown, the maximum distance H1 between the top surface of the limiting member 130 and the bearing surface 101 refers to the maximum distance between the outer surface of the limiting member 130 and the bearing surface 101.

[0073] In some embodiments, the maximum distance H1 between the top surface of the limiting member 130 and the bearing surface 101 is 0-3 mm smaller than the thickness H2 of the laminate 200. With this configuration, the height of the limiting member 130 is slightly smaller than or flush with the height of the laminate 200, which allows a small amount of dust accumulated on the front panel 205 to be washed away by rainwater, thus achieving the purpose of preventing dust accumulation.

[0074] In some embodiments, the limiting member 130 includes a limiting base 131 connected to the abutment member 120 and a limiting protrusion 150 connected to the limiting base 131. The minimum distance H5 between the limiting protrusion 150 and the bearing surface 101 is not less than the thickness H4 of the back panel 201 on the laminate 200. In this case, the minimum distance H3 between the limiting member 130 and the bearing surface 101 can be greater than the minimum distance H5 between the limiting protrusion 150 and the bearing surface 101. When the limiting member 130 is provided with the limiting protrusion 150, the limiting protrusion 150 is used to press against a portion of the back panel 201 of the laminate 200. When the limiting member 130 has the limiting base 131, the limiting base 131 is parallel to the bearing surface 101.

[0075] In some embodiments, the minimum distance H5 between the limiting protrusion 150 and the bearing surface 101 is 0.6mm to 1.5mm larger than the thickness H4 of the back panel 201 on the laminate 200. This arrangement allows the back panel 201 of the laminate 200 to have a certain margin when moving in the area between the limiting protrusion 150 and the bearing surface 101, ensuring that the back panel 201 can move to a certain extent during encapsulation.

[0076] In some embodiments, the width W1 of the limiting member 130 is 2mm to 7mm. The value of the width W1 of the limiting member 130 includes, but is not limited to: 2mm, 3mm, 4mm, 5mm, 6mm, 7mm or any range between the two mentioned above.

[0077] In some embodiments, the width W1 of the limiting member 130 is equal to the distance W3 between the edge of the back panel 201 and the edge of the front panel 205 on the laminate 200. See also Figure 2 As shown, the edge of the back panel 201 on the laminate 200 protrudes beyond the edge of the front panel 205, and the distance by which the edge of the back panel 201 protrudes beyond the edge of the front panel 205 is W3. This configuration ensures that, after encapsulation, the edge of the laminate 200 is completely secured to the frame, achieving a state where the abutment 120 abuts against the end face of the back panel 201 of the laminate 200, and the limiting member 130 abuts against the end face of the front panel 205 of the laminate 200. During encapsulation, this minimizes the risk of the front panel 205 shattering.

[0078] It should be noted that when the limiting member 130 includes the limiting protrusion 150, the width W1 of the limiting member 130 refers to the width of the limiting base 131. The width W1 of the limiting base 131 is its dimension along the width direction of the cavity-free frame.

[0079] In some embodiments, the width W1 of the limiting member 130 is smaller than the width W2 of the bearing surface 101. By setting the width of the limiting member 130 to be smaller than the width of the bearing surface 101, the laminations 200 with different widths for the front panel 205 and the back panel 201 are encapsulated.

[0080] In some embodiments, the limiting protrusion 150 is located at the end of the limiting member 130 away from the abutment member 120. The limiting protrusion 150 is located at the end away from the abutment member 120, which can both press against the protruding part of the back panel 201 and abut against the end face of the front panel 205, thereby improving the sealing fit, reducing the gap between the frame and the laminate 200, and reducing dust accumulation.

[0081] In some embodiments, the limiting protrusion 150 includes a connecting portion 151 and a bent portion 152. The connecting portion 151 and the bent portion 152 are generally bent structures. For example, see... Figure 1As shown, the bent structure is approximately "J" shaped. Connecting portion 151 is connected to limiting base 131. Bending portion 152 is connected to connecting portion 151 and extends towards the bottom surface of mounting groove 140. An auxiliary receiving area 153 for accommodating overflowing adhesive is formed between bending portion 152, connecting portion 151, and limiting base 131. Connecting portion 151 and part of limiting base 131 together abut against the end face of front panel 205 of laminate 200, and bending portion 152 abuts against part of front panel 205 of laminate 200. Bending portion 152 can limit front panel 205, and the outer side of bending portion 152 away from abutting member 120 can be used to abut against the end face of front panel 205, thus minimizing the risk of front panel 205 shattering during encapsulation.

[0082] In some embodiments, the length of the bend 152 extending toward the bottom surface of the mounting groove 140 is not greater than the distance W3 between the edge of the back panel 201 and the edge of the front panel 205 on the laminate 200.

[0083] In some embodiments, the extending direction of the bent portion 152 and the limiting base 131 are both parallel to the bearing surface 101. See also Figure 1 As shown, the surface of the bent portion 152 close to the bearing surface 101 is preferably designed as a flat surface, so that the bent portion 152 and the back panel 201 can have a larger contact area, which can play a role in distributing the force during mechanical load testing.

[0084] In some embodiments, the outer surface of the connection position between the connecting portion 151 and the bending portion 152 has a curved chamfered structure. The design of the outer surface of the connection position between the connecting portion 151 and the bending portion 152 with a curved chamfered structure makes it easier for the back panel 201 to be inserted into the mounting groove 140, thus improving installation convenience.

[0085] In some embodiments, the connecting portion 151 and the limiting base portion 131 have an included angle of 80° to 110°.

[0086] Preferably, the connecting portion 151 is perpendicular to the limiting base 131. The perpendicularity between the connecting portion 151 and the limiting base 131 can increase the contact area between the connecting portion 151 and the end face of the front panel 205, reduce the gap between them, and reduce dust accumulation.

[0087] In some embodiments, the surface of the abutment 120 located within the mounting groove 140 has an abutment protrusion 121. The abutment protrusion 121 is close to the bearing surface 101 and is used to abut against at least a portion of the end face of the back panel 201 of the fixed laminate 200.

[0088] In some embodiments, the surface of the abutment 120 located within the mounting groove 140 has a pressing protrusion 122. The pressing protrusion 122 is close to the retainer 130 and is used to assist adhesive overflow to the front panel 205 of the laminate 200.

[0089] In some embodiments, the bearing surface 101 has a plurality of adhesive overflow grooves 102. The adhesive overflow grooves 102 can hold a portion of the adhesive, thereby improving its adhesive strength and enhancing the connection between the back panel 201 and the bearing surface 101.

[0090] In some embodiments, the surface of the bearing surface 101 is generally planar, which can increase the contact area between the back panel 201 and the bearing surface 101 and improve the connection between the back panel 201 and the bearing surface 101.

[0091] In some embodiments, the inner wall of the overflow groove 102 gradually narrows from the bottom surface of the groove to the opening. This design enables the bonded parts after the adhesive has cured to form a structure that is larger inside and smaller outside, making it difficult for the bonded parts to detach from the overflow groove 102 and improving the connection between the back panel 201 and the bearing surface 101.

[0092] In some embodiments, the shape of the overflow groove 102 can be a regular shape or an irregular shape, such as a square groove, a circular groove, etc., and no specific limitation is made here.

[0093] In some embodiments, the number of slots in the overflow groove 102 is determined according to the width W2 of the bearing surface 101.

[0094] In some embodiments, the frame body 110 is a metal frame made of metal or alloy material, or a composite material frame made of composite material.

[0095] Preferably, the frame body 110 is a composite material frame made of composite materials. The materials of the composite material frame include polyurethane, glass fiber, etc., which have insulating properties. Therefore, the creepage distance of the photovoltaic module 10 using the composite material frame can theoretically be zero. To ensure that the battery cells 203 are not obstructed and considering the sealing of the encapsulant film, the size of the front panel 205 of the photovoltaic module 10 using the composite material frame in this application can be reduced. Compared with photovoltaic modules 10 of conventional technology, this application can effectively reduce the overall structural size. Here, creepage distance refers to the safe distance between the frame and charged bodies such as battery strings.

[0096] An embodiment of this application also provides a photovoltaic module 10.

[0097] A photovoltaic module 10 includes a laminate 200 and a cavity-less frame 100 as described in any of the above embodiments. See also Figure 2 As shown, Figure 2 This is a schematic diagram of the structure of a laminate 200 according to an embodiment of the present invention. The laminate 200 includes a back panel 201, a back adhesive film 202, a battery 203, a front adhesive film 204, and a front panel 205 stacked in sequence. The laminate 200 is encapsulated by a cavity-free frame 100. During encapsulation, the edge of the laminate 200 is encapsulated in the mounting groove 140 of the cavity-free frame 100.

[0098] In some of these embodiments, see Figure 2 The laminate 200 shown has a back panel 201 whose edges protrude beyond the front panel 205. The distance W3 between the edges of the back panel 201 and the front panel 205 on the laminate 200 is shown. Figure 3 As shown, Figure 3 This is a schematic diagram of the encapsulation of a cavity-less frame 100 and a laminate 200 according to an embodiment of the present invention. The laminate 200 is encapsulated by the cavity-less frame 100. A portion of the back panel 201 of the laminate 200 is located on the bearing surface 101. The end face of the back panel 201 of the laminate 200 can abut against the abutment 120. The end face of the front panel 205 of the laminate 200 abuts against the end face of the limiting member 130. A portion of the back panel 201 of the laminate 200 abuts against the surface of the limiting member 130 facing the bearing surface 101.

[0099] In some embodiments, when the limiting member 130 includes a limiting protrusion 150, the limiting protrusion 150 engages with the back panel 201, specifically, the bent portion 152 engages with the back panel 201. The connecting portion 151 and part of the limiting base 131 together abut against the end face of the front panel 205 of the laminate 200, and the bent portion 152 abuts against part of the back panel 201 of the laminate 200. The bent portion 152 can limit the back panel 201, and the outer side of the bent portion 152 away from the abutment member 120 can be used to abut against the end face of the front panel 205, thus minimizing the risk of the front panel 205 shattering during encapsulation.

[0100] In some embodiments, there may be multiple moldless cavity frame 100s. When there are multiple moldless cavity frame 100s, the end faces of adjacent moldless cavity frame 100s can be joined by bevels to achieve a 90° angle splicing between adjacent moldless cavity frame 100s. During processing, the end faces of the moldless cavity frame 100s can be cut to make the end faces of the moldless cavity frame 100s beveled at 45°, which facilitates splicing.

[0101] In some embodiments, the lengths of the cavity-less border 100 may be equal or unequal. For example, the cavity-less border 100 may include a long border and a short border to fit the long and short sides of the laminate 200, respectively.

[0102] In some embodiments, the length of the cavity-less frame 100 can be set according to the length or width of the laminate 200, and no specific limitation is made here.

[0103] In some embodiments, the adhesive used in the mounting groove 140 during encapsulation can be the glue used in the photovoltaic field, without specific limitations.

[0104] In some embodiments, the front panel 205 and the back panel 201 described above can be independently selected from photovoltaic glass panels.

[0105] In summary, compared with traditional technologies, the cavity-free border 100 of this application has the following beneficial effects:

[0106] (1) Cost reduction: This application eliminates the cavity structure, eliminates the need for corner brackets, and reduces the material of the frame body 110 by one side wall. The dimensions of other side walls, such as the support part 112 and the mounting part 113, can be reduced. While ensuring load-bearing capacity through structural optimization, the material of non-critical parts is effectively reduced, thereby achieving cost reduction of frame material.

[0107] (2) Airborne reliability: By using the limiting member 130 or the limiting protrusion 150 to restrain the back panel 201 of the laminate 200, the airborne load strength can be guaranteed to the maximum extent.

[0108] (3) Dust prevention: Based on the safety and reliability of the airborne load, the maximum height of the bearing surface 101 of the limiting component 130 is not higher than that of the front panel 205. Therefore, a small amount of dust on the front panel 205 can be more easily washed away by rainwater, thus achieving the purpose of dust prevention.

[0109] (4) Aesthetically pleasing appearance: The composite material frame of this application is preferably made of composite material, which can be made of a variety of colors such as black and dark blue, forming the same color effect as the battery 203, and has a better visual effect. Since this application reduces the size of the limiting member 130 and the abutment member 120, even if a metal frame made of metal or alloy material is used, such as an aluminum frame, visual comfort can be improved.

[0110] (5) The cavity-free frame 100 has a variety of assembly forms: This application eliminates the cavity of the frame, so the long and short frames can be connected by an integral folding method, and the two cavity-free frames 100 at the beginning and end are connected by a buckle to achieve a closed loop connection.

[0111] In the above embodiments, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions in other embodiments.

[0112] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0113] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention. Therefore, the scope of protection of this patent should be determined by the appended claims.

Claims

1. A cavity-free frame (100), characterized in that, The device includes a frame body (110), an abutment (120), and a limiting member (130). The frame body (110) includes a bearing portion (111), a support portion (112), a mounting portion (113), and a reinforcing portion (114). The bearing portion (111) and the mounting portion (113) are spaced apart. The support portion (112) is disposed between the bearing portion (111) and the mounting portion (113) and connects the bearing portion (111) and the mounting portion (113). The surface of the bearing portion (111) away from the support portion (112) forms a bearing surface (101). One end of the reinforcing portion (114) is connected to the bearing portion (111), and the other end is connected to the support portion (112). The abutment (120) is connected to the first end of the bearing portion (111). The limiting member (130) is connected to the end of the abutment member (120) away from the bearing part (111). The limiting member (130), the abutment member (120) and the bearing surface (101) form a mounting groove (140) for mounting the laminate (200). The opening of the mounting groove (140) faces the second end of the bearing part (111). The frame body (110) also includes a connecting mating part (160). One end of the connecting mating part (160) is connected to the support part (112). The other end of the connecting mating part (160) extends away from the support part (112) along the plane where the support part (112) is located, and the end is curled. The connecting mating part (160) is used to realize the connection between the adjacent frame body (110) and the connecting buckle.

2. The cavityless frame (100) according to claim 1, characterized in that, The distance between the position where the reinforcing part (114) is connected to the bearing part (111) and the position where the bearing part (111) and the support part (112) are connected is L1, and the width of the bearing part (111) is D1, wherein L1≥1 / 4D1.

3. The cavity-less frame (100) according to claim 2, characterized in that, L1 is 1 / 2D1~D1.

4. The cavityless frame (100) according to claim 1, characterized in that, The distance between the position where the reinforcing part (114) is connected to the support part (112) and the position where the bearing part (111) and the support part (112) are connected is L2, and the height of the support part (112) is D2, wherein L2≤2 / 3D2.

5. The cavity-less frame (100) according to claim 4, characterized in that, L2 is 1 / 3D2 to 2 / 3D2.

6. The cavityless frame (100) according to any one of claims 1 to 5, characterized in that, The cavity-free frame (100) also satisfies at least one of the following conditions: (1) The connection between the support part (112) and the bearing part (111) is a rounded transition; (2) The connection between the support part (112) and the mounting part (113) is a rounded transition.

7. The cavity-less frame (100) according to claim 6, characterized in that, The cavity-free frame (100) also satisfies at least one of the following conditions: (1) The radius R1 of the fillet at the connection between the support part (112) and the bearing part (111) is between 0.25 and 2. (2) The radius R2 of the rounded corner at the connection between the support part (112) and the mounting part (113) is between 0.25 and 2.

8. The cavity-free frame (100) according to any one of claims 1 to 5 and 7, characterized in that, The cavity-free frame (100) also satisfies at least one of the following conditions: (1) The frame body (110) further includes a thickened portion (115), which is connected to the support portion (112) and protrudes from the surface of the support portion (112) for connection of the reinforcing portion (114); (2) The end face of the support part (112) and the first end face of the bearing part (111) and the end face of one end of the mounting part (113) are flush; (3) The abutting part (120) is flush with the supporting part (112).

9. The cavityless frame (100) according to any one of claims 1 to 5 and 7, characterized in that, The maximum distance H1 between the top surface of the limiting member (130) and the bearing surface (101) is not greater than the thickness H2 of the laminate (200), the minimum distance H3 between the limiting member (130) and the bearing surface (101) is not less than the thickness H4 of the back panel (201) on the laminate (200), the bearing surface (101) is used to support part of the back panel (201) of the laminate (200), the abutting member (120) is used to abut against the end face of the back panel (201) of the laminate (200), the end face of the limiting member (130) is used to abut against the end face of the front panel (205) of the laminate (200), and the surface of the limiting member (130) facing the bearing surface (101) is used to press against part of the back panel (201) of the laminate (200).

10. A photovoltaic module (10), characterized in that, The device includes a laminate (200) and a cavity-less frame (100) as described in any one of claims 1 to 9. The laminate (200) includes a back panel (201), a back adhesive film (202), a battery (203), a front adhesive film (204), and a front panel (205) stacked in sequence. The laminate (200) is encapsulated by the cavity-less frame (100). During encapsulation, the edge of the laminate (200) is encapsulated in the mounting grooves (140) of the cavity-less frames (100).

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