Steel frame corner connector assembly for solar assembly and machining method

Abstract

The invention relates to the technical field of photovoltaic module structures, in particular to a steel frame corner connector assembly for a solar assembly and a machining method, the end of a frame is not beveled by 45 degrees, so that frame waste is reduced, production cost is reduced, no sharp corner protrudes after the corner connector and the frame are assembled, and production efficiency is improved. The process of twisting angles on the frame is not needed; the backstop part is designed to be matched with the frame without 45-degree beveling, so that the line contact between the frame and the corner brace is changed into the surface contact between the frame and the backstop part, and the problem of plate explosion caused by over-pushing is solved; after the photovoltaic glass plate is clamped and mounted, the height of the formed cleaning chamber is lower than that of the frame, so that rainwater with dust can be guided into the cleaning chamber before spreading through the frame and then is discharged from the drainage hole, and water with dust is prevented from being dried in the sun on one side of the frame; therefore, dust is gradually accumulated on one side of the frame to form a dust accumulation zone.

Description

Technical Field

[0001] The present invention relates to the technical field of photovoltaic module structures, and in particular to a steel frame corner bracket assembly for a solar module and a processing method thereof. Background Art

[0002] The life of solar photovoltaic modules is mainly affected by the life of the packaging materials, the packaging process and the use environment. The packaging materials of solar photovoltaic modules include solar photovoltaic module frames and corner brackets. The photovoltaic module frame refers to the fixed frame of the photovoltaic solar panel assembly. The corner bracket is used to connect the two photovoltaic module frames to each other and clamp the photovoltaic glass. As the price of photovoltaic modules on the market continues to fall, the proportion of the frame in the module cost continues to rise. In this environment where the module price continues to fall, each module manufacturer will definitely put the cost-saving plan of the frame on the agenda.

[0003] The main causes of dust and water accumulation on the front of PV panels include the interaction between dust and water flow. When rainwater flows over the surface of PV panels, dust is carried by the water flow and deposited in certain areas of the panels, especially near the frame. Since the frame of PV panels is usually made of aluminum and its height is slightly higher than the front glass of the panel, the water flow is blocked at the frame, forming a dust accumulation zone.

[0004] In the prior art, after the frame is formed by cold bending, a certain margin needs to be left, and then a 45° bevel is cut on this part of the margin. The cut part is wasted and the hole is punched later. During installation, one end of the corner bracket will be inserted into the 45° bevel of one of the frames, and the folded edge of the corner bracket will be in line contact with one side of the frame and will not move. Then the other end will be inserted into the 45° bevel of the other frame for framing. When the thrust is too large during framing, the side of the frame in contact with the folded edge of the corner bracket will burst due to pressure. When the two 45° bevels are fitted together, the ends of the two frames will jointly form a 90° angle, and then glue will be applied to put the photovoltaic glass between the clamping parts of the two frames.

[0005] Therefore, there are three main problems with the photovoltaic frame corner code components in the existing technology: first, the frame is higher than the surface of the photovoltaic glass, and rainwater brings dust, resulting in dust accumulation; second, 45° bevel cutting will produce waste; third, the frame has a line contact when the 45° bevel is against the corner code, and over-pushing will cause the board to explode.

[0006] The above information disclosed in this Background section is only for enhancement of understanding of the background of the present disclosure and therefore it may contain information that does not form the prior art that is already known to a person of ordinary skill in the art. Summary of the Invention

[0007] The purpose of the present invention is to redesign the frame corner code assembly so that it can solve the three problems of dust accumulation belt, waste generation and over-pushing plate in a small change, so as to solve the above-mentioned shortcomings in the technology.

[0008] In order to achieve the above-mentioned purpose, the present invention provides the following technical solutions: a steel frame corner bracket assembly for a solar panel, used for clamping and fixing photovoltaic glass, comprising a corner bracket and a frame, the frame comprising a receiving portion for receiving the corner bracket and a clamping portion for receiving the photovoltaic glass, the plane of the frame end being perpendicular to its own length direction, a stopper being fixedly installed on the outside of the middle corner of the corner bracket, the stopper being close to both sides of the two frames and parallel to the frame end, when the photovoltaic glass is located in the clamping portion, a gap is formed between the surface of the photovoltaic glass and the top surface of the inner cavity of the stopper to form a clearing chamber, and a drainage hole communicating with the clearing chamber is opened on the stopper;

[0009] By changing the end of the frame from an inclined surface to a flat surface and installing a stopper that matches the end of the frame on the corner code, a cleaning chamber is formed while preventing the over-pushing plate, so that the dust in the dust accumulation belt is discharged into the cleaning chamber with the water flow.

[0010] Preferably, the stop portion includes two vertical plates fixed to the outer side of the corner of the corner code, and the top and bottom of the two vertical plates are respectively fixedly installed with a top plate and a bottom plate. There is a gap between the bottom surface of the top plate and the surface of the photovoltaic glass to form a clearing chamber, and the two sides of the top plate, vertical plate and bottom plate are respectively parallel to the two adjacent ends of the frame.

[0011] Preferably, the frame includes a first part and a second part that are attached to the top and bottom of the vertical plate, and also includes a third part that is attached to the top surface of the angle code, a fourth part that is attached to the bottom surface of the angle code, a fifth part fixedly connected between the third part and the fourth part, a sixth part that is attached to the top plate, and a seventh part that is fixedly installed on one side of the sixth part close to the third part. The first part and the second part are fixedly connected to the third part and the fourth part respectively, and a receiving part for accommodating the angle code is formed between the second part, the third part, the fourth part and the fifth part, and a clamping part for accommodating the photovoltaic glass is formed between the first part, the third part and the seventh part.

[0012] Preferably, the top surface of the top plate is provided with a fan-shaped groove with gradually increasing depth, a rectangular opening connected to the fan-shaped groove is provided at one corner of the top plate, and the width of the top plate is the sum of the width of the rectangular opening and the width of the third portion.

[0013] Preferably, a glue overflow cavity is formed between the sixth part, the seventh part, the first part and the surface of the photovoltaic glass.

[0014] Preferably, the cross section of the angle code is set to be I-shaped, a blind groove station is opened on the top of the angle code, a bridge-type station is slidably installed in the blind groove station, and the bridge-type station is fixedly connected to the bottom surface of the third part.

[0015] Preferably, a tensile groove is provided on the bottom surface of the angle bracket, a tensile block is provided in the tensile groove, and the tensile block is fixedly connected to the top surface of the fourth part.

[0016] Preferably, the tensile block is a D-shaped rivet point, the tensile groove cooperates with the D-shaped rivet point, and the arcuate side of the D-shaped anchor point is close to one side of the angle code.

[0017] In a second aspect, the present invention further provides a processing method for processing the steel frame corner bracket assembly for a solar module according to any one of claims 1 to 9, the processing method comprising the steps of:

[0018] S1: The frame is made by cold-bending process according to the drawing, without 45° bevel cutting;

[0019] S2: The diagonal bracket and the stopper are made of one piece by die casting;

[0020] S3: Welding the D-shaped rivet point and the bridge-type station on the stopper;

[0021] S4: Pack the frames and corners for shipment.

[0022] In the above technical solution, the technical effects and advantages provided by the present invention are:

[0023] 1. The present invention does not perform 45° bevel cutting on the frame end, which not only reduces the generation of frame waste, thereby reducing production costs, but also leaves no sharp corners protruding after the corner brackets and frame are assembled, and does not require the process of rubbing the frame corners;

[0024] 2. The present invention designs a stopper that cooperates with a frame without a 45° bevel, so that the line contact between the frame and the corner code is changed to a surface contact between the frame and the stopper, thereby solving the problem of panel explosion caused by over-pushing;

[0025] 3. At the same time, after the photovoltaic glass panels are clamped and installed, the height of the cleaning chamber formed by the present invention is lower than the height of the frame, so that rainwater carrying dust will be diverted into the cleaning chamber before spreading over the frame, and then discharged from the drainage hole, thereby preventing the dust-carrying water from drying on one side of the frame, causing dust to gradually accumulate on one side of the frame to form a dust accumulation belt;

[0026] 4. In the present invention, the seventh part is fixedly mounted on the side of the sixth part close to the third part, thereby forming not only a cleaning chamber but also an overflow glue chamber. This allows for excessive glue application during installation of the photovoltaic glass panel to flow into the overflow glue chamber rather than overflowing onto the photovoltaic glass surface.

[0027] 5. The present invention not only solves the problem of anti-torsion bursting of the plate, but also improves the anti-pullout capability by coordinating the blind groove station, the bridge type station, the D-shaped rivet point and the tensile groove. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the following is a brief introduction to the drawings required for use in the embodiments. Obviously, the drawings described below are only some embodiments recorded in the present invention. For ordinary technicians in this field, other drawings can also be obtained based on these drawings.

[0029] Figure 1 It is a schematic diagram of the overall structure of the present invention;

[0030] Figure 2 This is a schematic diagram of the installation of the photovoltaic glass and frame corner brackets of the present invention;

[0031] Figure 3 Schematic diagram of the cleaning chamber and the overflow glue chamber of the present invention;

[0032] Figure 4 This is a split cross-sectional view of the corner bracket and frame of the present invention;

[0033] Figure 5 This is a schematic diagram of the connection between the corner bracket and the frame of the present invention;

[0034] Figure 6 This is a schematic diagram of the connection between the angle bracket and the stopper of the present invention;

[0035] Figure 7 It is a schematic diagram of the connection between the drainage hole and the stopper of the present invention.

[0036] Description of reference numerals:

[0037] 1. Corner code; 2. Frame; 2a. First part; 2b. Second part; 2c. Third part; 2d. Fourth part; 2e. Fifth part; 2f. Sixth part; 2g. Seventh part; 3. Accommodation part; 4. Clamping part; 5. Stop part; 5a. Vertical plate; 5b. Top plate; 5c. Bottom plate; 6. Cleaning chamber; 7. Drain hole; 8. Fan-shaped groove; 9. Rectangular opening; 10. Overflow glue chamber; 11. Blind groove station; 12. Bridge-type station; 13. Tensile groove; 14. Tensile block. DETAILED DESCRIPTION

[0038] In order to help those skilled in the art better understand the technical solutions in this application, the technical solutions in the embodiments of this application will be clearly and completely described below. Obviously, the embodiments described are only part of the embodiments of this application, not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by those skilled in the art without making any creative efforts shall fall within the scope of protection of this application.

[0039] In order to better understand the above technical solution, the above technical solution will be described in detail below with reference to the accompanying drawings and specific implementation methods.

[0040] The present invention provides Figure 1-7 The steel frame corner bracket assembly for solar panels shown in the figure is used to clamp and fix photovoltaic glass, including a corner bracket 1 and a frame 2. In order to solve the problem that the frame 2 needs to be beveled at 45 degrees during the production process, and the waste caused by the cut-off waste is wasted, we directly use the cold bending forming process to make the frame 2 without beveling; then a stopper 5 composed of two vertical plates 5a, a top plate 5b and a first bottom plate 5c is directly fixed on the outside of the corner of the corner bracket 1. The end faces of the two frames 2 are in contact with the two sides of the stopper 5, so that The two frames 2 and the stopper 5 together form a 90° angle to wrap the four corners of the photovoltaic glass; at the same time, in order to prevent the frame 2 from pushing the board too much, the frame 2 is designed to be an integrated style consisting of the first part 2a, the second part 2b, the third part 2c, the fourth part 2d, the fifth part 2e, the sixth part 2f, and the seventh part 2g, so that the accommodating part 3 for accommodating the corner code 1 is formed between the fourth part 2d and the fifth part 2e, and the clamping part 4 for accommodating the photovoltaic glass is formed between the first part 2a, the third part 2c and the seventh part 2g, and the first part 2 a and the second part 2b are squeezed against the side wall of the vertical plate 5a, so that the fourth part 2d is squeezed against the side wall of the bottom plate 5c, and the sixth part 2f is squeezed against the top plate 5b. Compared with the linear contact between the frame 2 and the corner code 1 in the prior art, the newly designed frame 2 is in four-surface contact with the stopper 5, thereby solving the problem of over-pushing the plate; at the same time, we fix the seventh part 2g on the side of the sixth part 2f close to the third part 2c, so that when the photovoltaic glass is placed in the clamping part 4, there is a gap between the bottom surface of the top plate 5b and the surface of the photovoltaic glass to form a cleaning chamber 6. The height of this gap depends on the thickness of the seventh part 2g. At this time, once rainwater carries dust and falls on the surface of the photovoltaic glass, since the height of the cleaning chamber 6 is lower than the height of the sixth part 2f, that is, the height of the frame 2, the water flow will first carry the dust into the cleaning chamber 6 before overflowing the frame 2. At the same time, we have opened a drainage hole 7 on the stopper 5 that is connected to the cleaning chamber 6. The water flow will carry the dust through the cleaning chamber 6 and the drainage hole 7 and be discharged from the surface of the photovoltaic glass, instead of accumulating near the frame 2 to form a dust accumulation belt as in the prior art;

[0041] Furthermore, since the seventh portion 2g is fixed to the side of the sixth portion 2f close to the third portion 2c, and the width of the seventh portion 2g is smaller than that of the sixth portion 2f, a glue overflow chamber 10 is formed between the sixth portion 2f, the seventh portion 2g, the first portion 2a, and the surface of the photovoltaic glass. Thus, when the photovoltaic glass is installed and glue is applied, excess glue can enter the glue overflow chamber 10 instead of overflowing onto the surface of the photovoltaic glass.

[0042] In order to further speed up the drainage of water, we have opened a fan-shaped groove 8 with gradually increasing depth on the top surface of the top plate 5b. A rectangular opening 9 connected to the fan-shaped groove 8 is opened at one corner of the top plate 5b. The width of the top plate 5b is the sum of the width of the rectangular opening 9 and the width of the third part 2c. In this way, if rainwater does not have time to drain from the cleaning chamber 6, when the water level rises to a certain height, the water will pass through the rectangular opening 9 of the fan-shaped groove 8, enter the deepest part of the fan-shaped groove 8, and then be discharged along the gradually rising slope of the fan-shaped groove 8;

[0043] At the same time, in order to prevent the frame 2 and the corner bracket 1 from twisting and causing the board to burst, the cross section of the corner bracket 1 is set to an I-shape. A blind groove station 11 is opened on the top of the corner bracket 1. A bridge-shaped station 12 is slidably installed in the blind groove station 11. The bridge-shaped station 12 is fixedly connected to the bottom surface of the third part 2c, so that the blind groove station 11 and the bridge-shaped station 12 are in interference fit;

[0044] Finally, in order to quickly install the corner bracket 1 and the frame 2, we opened a tensile groove 13 on the bottom surface of the corner bracket 1, and a tensile block 14 was placed in the tensile groove 13. The tensile block 14 was fixedly connected to the top surface of the fourth part 2d. At the same time, in order to further improve the pull-out resistance, the tensile block 14 was set as a D-shaped rivet point. The tensile groove 13 cooperates with the D-shaped rivet point. The arc side of the D-shaped anchor point is close to one side of the corner bracket 1. After the D-shaped rivet point and the tensile groove 13 interfere with each other, the corner bracket 1 and the frame 2 are stable and not easy to fall off.

[0045] At the same time, we provide a processing method for processing the above-mentioned steel frame 2 corner code 1 assembly, including the following steps:

[0046] S1: According to the drawing, the frame 2 is made by cold-bending forming process without 45° bevel cutting. This can solve the problem of waste generation and save the raw materials of the frame 2. At the same time, without bevel cutting, there are no sharp corners after framing, and the process of rubbing the corners after framing the frame 2 can be eliminated, thus reducing one process.

[0047] S2: The angle bracket 1 and the stopper 5 are integrally manufactured by die casting. The integral die casting can reduce the generation of processing waste of the angle bracket 1;

[0048] S3: Welding a D-shaped rivet point and a bridge-type station 12 on the stopper 5. The D-shaped rivet point cooperates with the tensile groove 13 on the angle code 1 to achieve an anti-pullout effect, and the bridge-type station 12 cooperates with the blind groove station 11 to achieve an anti-torsion burst effect.

[0049] S4: The frame 2 and the corner code 1 are packaged and shipped. This part is the same as the existing technology.

[0050] It is important to note that the construction and arrangement of the present application shown in a number of different exemplary embodiments are illustrative only. Although only a few embodiments are described in detail in this disclosure, those who refer to this disclosure should readily understand that many modifications are possible without materially departing from the novel teachings and advantages of the subject matter described in this application (e.g., size, scale, structure, shape and proportion of various elements, and parameter values (e.g., temperature, pressure, etc.), mounting arrangements, use of materials, colors, orientation changes, etc.).

Claims

1. A steel frame corner bracket assembly for a solar panel, used for clamping and fixing photovoltaic glass, comprising a corner bracket (1) and a frame (2), wherein the frame (2) comprises a receiving portion (3) for receiving the corner bracket (1) and a clamping portion (4) for receiving the photovoltaic glass, characterized in that: The plane of the end of the frame (2) is perpendicular to its own length direction, and a stopper (5) is fixedly installed on the outside of the middle corner of the corner code (1). The stopper (5) is close to the two sides of the two frames (2) and is parallel to the end of the frame (2). When the photovoltaic glass is located in the clamping part (4), a gap exists between the surface of the photovoltaic glass and the top surface of the inner cavity of the stopper (5) to form a clearing chamber (6), and a drainage hole (7) is opened on the stopper (5) and is connected to the clearing chamber (6); By changing the end of the frame (2) from an inclined surface to a flat surface and installing a stopper (5) matched with the end of the frame (2) on the corner code (1), a cleaning chamber (6) is formed while preventing the over-pushing plate, so that dust in the dust accumulation belt is discharged into the cleaning chamber (6) along with the water flow.

2. The steel frame corner bracket assembly for a solar panel according to claim 1, characterized in that: The stopper (5) comprises two vertical plates (5a) fixed to the outer sides of the corners of the corner code (1); a top plate (5b) and a bottom plate (5c) are fixedly mounted on the top and bottom of the two vertical plates (5a), respectively; a clearance chamber (6) is formed between the bottom surface of the top plate (5b) and the surface of the photovoltaic glass; and both sides of the top plate (5b), the vertical plates (5a) and the bottom plate (5c) are respectively parallel to the ends of two adjacent frames (2).

3. The steel frame corner bracket assembly for a solar panel according to claim 2, characterized in that: The frame (2) includes a first part (2a) and a second part (2b) attached to the top and bottom of the vertical plate (5a), and also includes a third part (2c) attached to the top surface of the corner code (1), a fourth part (2d) attached to the bottom surface of the corner code (1), a fifth part (2e) fixedly connected between the third part (2c) and the fourth part (2d), a sixth part (2f) attached to the top plate (5b), and a seventh part (2g) fixedly installed on one side of the sixth part (2f) close to the third part (2c). The first part (2a) and the second part (2b) are fixedly connected to the third part (2c) and the fourth part (2d), respectively. A receiving part (3) for receiving the corner code (1) is formed between the second part (2b), the third part (2c), the fourth part (2d) and the fifth part (2e), and a clamping part (4) for receiving the photovoltaic glass is formed between the first part (2a), the third part (2c) and the seventh part (2g).

4. The steel frame corner bracket assembly for a solar panel according to claim 3, characterized in that: The top surface of the top plate (5b) is provided with a fan-shaped groove (8) with a gradually increasing depth, a rectangular opening (9) communicating with the fan-shaped groove (8) is provided at one corner of the top plate (5b), and the width of the top plate (5b) is the sum of the width of the rectangular opening (9) and the width of the third portion (2c).

5. The steel frame corner bracket assembly for a solar panel according to claim 3, characterized in that: An overflow glue cavity (10) is formed between the sixth part (2f), the seventh part (2g), the first part (2a) and the photovoltaic glass surface.

6. The steel frame corner bracket assembly for a solar panel according to claim 3, characterized in that: The cross section of the angle code (1) is set to be an I-shape, and a blind groove station (11) is opened on the top of the angle code (1), and a bridge-type station (12) is slidably installed in the blind groove station (11), and the bridge-type station (12) is fixedly connected to the bottom surface of the third part (2c).

7. The steel frame corner bracket assembly for a solar panel according to claim 6, characterized in that: The bottom surface of the angle code (1) is provided with a tensile groove (13), a tensile block (14) is provided in the tensile groove (13), and the tensile block (14) is fixedly connected to the top surface of the fourth part (2d).

8. The steel frame corner bracket assembly for a solar panel according to claim 7, characterized in that: The tensile block (14) is a D-shaped rivet point, the tensile groove (13) cooperates with the D-shaped rivet point, and the arc edge of the D-shaped anchor point is close to one side of the angle code (1).

9. A processing method for processing the steel frame (2) corner bracket (1) assembly for solar panels according to any one of claims 1 to 9, characterized in that: The following steps are involved: S1: The frame (2) is manufactured by cold-bending forming process according to the drawing without 45° beveling; S2: The diagonal bracket (1) and the stopper (5) are integrally manufactured by die-casting; S3: Welding a D-shaped rivet point and a bridge-shaped station (12) on the stopper (5); S4: Pack the frame (2) and the corner code (1) for shipment.

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