A quick assembling process method for a photovoltaic module frame

Abstract

The application relates to the photovoltaic power generation technical field and provides a photovoltaic module frame rapid assembly process method, which comprises the following steps: bonding a photovoltaic cell module and a stainless steel corrugated back plate through structural glue to form a preliminary assembly structure; embedding a silica gel strip into the edges of the two long sides of the preliminary assembly structure to avoid structural glue overflow pollution of the assembly surface; sleeving a stainless steel frame into the edges of the two long sides of the preliminary assembly structure from the top, and realizing accurate positioning through the clamping groove of the stainless steel frame and the edges of the preliminary assembly structure; adopting a laser welding mode to weld and fix the splicing position of the stainless steel frame and the stainless steel corrugated back plate; and injecting sealing glue into the gap between the short side of the preliminary assembly structure and the folded edge of the stainless steel corrugated back plate. Through material innovation, structure optimization and process improvement, the application breaks through the multiple bottlenecks of the prior art in strength, efficiency and environmental adaptability, and provides a brand-new solution for photovoltaic module production in high-demand scenarios.

Description

Technical Field

[0001] This invention belongs to the field of photovoltaic power generation technology, and specifically relates to a rapid assembly process method for photovoltaic module frames. Background Technology

[0002] In the field of photovoltaic power generation, the frame and backsheet structure of photovoltaic modules directly affect their load-bearing capacity, deformation resistance, and service life. In existing technologies, the following solutions are typically used for photovoltaic modules in high wind pressure areas:

[0003] 1. Double-glass module + aluminum reinforcing rib structure: The strength is improved by adding aluminum reinforcing ribs inside the double-glass module. However, the rigidity and corrosion resistance of aluminum are limited. The module deforms significantly under long-term load, which can easily lead to microcracks in the cells. In addition, the bonding between the aluminum reinforcing ribs and the double-glass module depends on structural adhesive, which is complicated and has a long curing time, making it difficult to meet the needs of industrial mass production.

[0004] 2. Traditional aluminum frame + full frame adhesive coating process: The module is surrounded by an aluminum frame, which is bonded to the module with structural adhesive. The frame needs to be designed with overflow grooves to prevent adhesive from overflowing and contaminating the surface. However, the aluminum frame is not strong enough, and the curing process of the structural adhesive is time-consuming (usually several hours), which seriously affects production efficiency. At the same time, aluminum is easily corroded in the high salt spray environment of the coast, leading to frame failure.

[0005] The core drawbacks of the above solution are: limited material performance: the strength and corrosion resistance of aluminum frames and reinforcing ribs are difficult to meet the long-term use requirements of high wind pressure and high corrosion environment; low process efficiency: the structural adhesive application and curing process is cumbersome, and the problem of adhesive overflow affects the appearance of the module and the power generation efficiency; structural redundancy: traditional modules are equipped with frames on all four sides, which results in high material costs, and the short frames contribute little to the improvement of strength, leaving room for design optimization.

[0006] Therefore, a method is urgently needed to solve at least one of the above problems. Summary of the Invention

[0007] This application provides a rapid assembly process for photovoltaic module frames, aiming to solve the problems of material performance limitations, low process efficiency, and structural redundancy in photovoltaic modules for high wind pressure areas.

[0008] In a first aspect, this application provides a rapid assembly process method for photovoltaic module frames, the method comprising:

[0009] Photovoltaic cell modules are bonded to stainless steel corrugated back sheets with structural adhesive to form a preliminary module structure. The stainless steel corrugated back sheets are produced continuously by roll forming, with a thickness range of 0.5mm to 0.7mm to meet the strength requirements of different load areas.

[0010] Molded silicone strips are embedded in the two long edges of the preliminary component structure. The molded silicone strips serve as a sealing and buffering material and are snapped between the photovoltaic cell module and the subsequently installed stainless steel frame to prevent structural adhesive from overflowing and contaminating the component surface.

[0011] The stainless steel frame is inserted from above into the two long edges of the preliminary component structure. The stainless steel frame is precisely positioned by its slots and the edges of the preliminary component structure. The stainless steel frame is only set on the two long edges of the preliminary component structure, while the short edges are protected by the folded edges of the stainless steel corrugated back plate.

[0012] Laser welding is used to weld and fix the splicing position of the stainless steel frame and the stainless steel corrugated back plate; sealant is injected into the gap between the short side of the preliminary component structure and the folded edge of the stainless steel corrugated back plate to enhance the sealing and durability of the component.

[0013] In some embodiments, the process of bonding the photovoltaic cell module to the stainless steel corrugated back plate with structural adhesive to form a preliminary module structure includes: uniformly applying structural adhesive to the back of the photovoltaic cell module or the bonding surface of the stainless steel corrugated back plate, wherein the application area of ​​the structural adhesive covers a range of at least 20 mm inward from the edge of the photovoltaic cell module; and then, after the two are tightly bonded together by vacuum adsorption or tooling fixtures, allowing them to stand for 10-30 minutes to complete the preliminary bonding and fixing.

[0014] In some embodiments, the cross-sectional shape of the molded silicone strip is rectangular, trapezoidal, or an irregular structure with barbed protrusions. When embedded, one side of the silicone strip is tightly fitted to the side of the photovoltaic cell module, and the other side is reserved with a compression amount of 0.5-1mm between it and the inner wall of the slot of the stainless steel frame to form an elastic sealing buffer layer.

[0015] In some embodiments, the length of the molded silicone strip is consistent with the length of the long side of the initial component structure, and both ends extend to the inner side of the stainless steel corrugated back plate folded edge by 5-10mm, so as to cover the periphery of the welding area between the frame and the back plate and avoid welding spatter contaminating the component surface.

[0016] In some embodiments, the inner wall of the slot of the stainless steel frame is provided with a limiting protrusion or groove that matches the edge of the stainless steel corrugated back plate. When inserted, the bottom of the slot is flush with the upper surface of the stainless steel corrugated back plate, and the two side walls of the slot abut against the side of the photovoltaic cell module and the outer side of the molded silicone strip, respectively, forming a three-dimensional positioning structure.

[0017] In some embodiments, the laser welding method for fixing the splicing position of the stainless steel frame and the stainless steel corrugated back plate includes: mechanically grinding or chemically cleaning the splicing position to remove the surface oxide layer before welding; using a pulsed laser with a wavelength of 1064nm, setting the laser power to 800-1200W, controlling the welding speed at 20-30mm / s, using 308 stainless steel welding wire as filler material, and forming a continuous or intermittent fillet weld at the overlap of the frame and the back plate, with a weld height of not less than 1.5mm.

[0018] In some embodiments, after the laser welding is completed, the weld is visually inspected and subjected to penetrant testing to remove components with pores or cracks on the surface. Qualified welds are passivated by applying stainless steel passivation liquid to remove the oxide discoloration layer on the weld surface and restore the corrosion resistance of the material.

[0019] In some embodiments, the width of the gap is 1-3mm. Before injection, the two sides of the gap are cleaned of dust. Silicone-based sealant or polyurethane sealant is used and injected evenly along the gap using an automatic dispensing device to ensure that the sealant completely fills the gap and the surface is smooth. After injection, it is left to stand for 20-40 minutes to allow the sealant to initially cure.

[0020] In some embodiments, the short side of the stainless steel corrugated back panel is formed by roll bending process, the bending angle of the fold is 90°±5°, the fold height is 8-12mm, a 2-3mm glue injection gap is reserved between the inner side of the fold and the short side edge of the photovoltaic cell module, and the outer side forms a protective edge structure flush with the long side stainless steel frame.

[0021] In some embodiments, both the stainless steel frame and the stainless steel corrugated back panel are made of stainless steel sheet. The yield strength of the stainless steel corrugated back panel is not less than 205 MPa, and the surface is brushed or sandblasted to enhance the adhesion of the structural adhesive and the surface roughness of the welded area.

[0022] In existing technologies, there is no technical solution that combines a stainless steel frame with a stainless steel corrugated back panel via laser welding, uses silicone strips instead of structural adhesive for sealing, and only sets the frame on the long side. Those skilled in the art are generally limited to aluminum frames and full-frame adhesive coating processes, failing to realize that material replacement (stainless steel), structural simplification (eliminating the short frame), and process innovation (laser welding, silicone strip snap-fit) can simultaneously solve the problems of strength, efficiency, and durability. Therefore, the technical solution of this invention is not a simple improvement on existing technologies, but a breakthrough innovation addressing industry pain points.

[0023] Against this backdrop, the rapid assembly process for photovoltaic module frames provided in this application utilizes laser welding of a stainless steel frame and a stainless steel corrugated backsheet to form an integral load-bearing structure. These two elements synergistically enhance module stiffness, significantly increasing load-bearing capacity compared to traditional aluminum frame solutions. This effectively reduces module deflection under high wind pressure and minimizes the risk of microcracks in the solar cells. Stainless steel exhibits far superior corrosion resistance compared to aluminum components, making it particularly suitable for coastal high-salt-spray environments and extending module lifespan. The corrugated backsheet is produced continuously through roll forming, with adjustable thickness (0.5mm~0.7mm) to meet the strength requirements of different load-bearing regions, offering high flexibility. Molded silicone strips replace traditional structural adhesive for filling the gap between the frame and module, avoiding adhesive overflow contamination and eliminating the need to wait for adhesive curing before proceeding directly to subsequent assembly processes. Stainless steel frames are only installed on the long sides, while the short sides utilize the corrugated backsheet's folded edges to form protective edges, reducing the material required for two short frame sections, lowering costs and weight, and simplifying assembly steps. The short-side gap is filled with sealant and then sealed with a silicone strip on the long side to form a double-sealing structure, which improves the waterproof performance of the component. Laser welding uses 308 welding wire to ensure the strength and corrosion resistance of the weld and avoid the long-term failure problem of traditional bonding processes.

[0024] In summary, this invention, through material innovation, structural optimization, and process improvement, overcomes multiple bottlenecks in strength, efficiency, and environmental adaptability of existing technologies, providing a brand-new solution for the production of photovoltaic modules in demanding scenarios.

[0025] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and do not limit this application. Attached Figure Description

[0026] To more clearly illustrate the technical solutions of the embodiments of this application, the drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0027] Figure 1 This is a schematic flowchart illustrating the steps of a rapid assembly process for a photovoltaic module frame according to an embodiment of this application;

[0028] Figure 2 This is a schematic diagram of the first structure of a photovoltaic module frame provided in an embodiment of this application;

[0029] Figure 3 This is a partially enlarged schematic diagram of the frame of a photovoltaic module provided in an embodiment of this application;

[0030] Figure 4 This is a schematic diagram of the second structure of the photovoltaic module frame provided in one embodiment of this application.

[0031] Explanation of reference numerals in the attached figures:

[0032] 10. Splicing position; 20. Sealant; 30. Structural adhesive; 40. Photovoltaic cell module; 50. Folded edge; 60. Glue injection position.

[0033] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and do not limit this application. Detailed Implementation

[0034] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0035] The flowchart shown in the attached diagram is for illustrative purposes only and does not necessarily include all content and operations / steps, nor does it necessarily have to be performed in the order described. For example, some operations / steps can be broken down, combined, or partially merged, so the actual execution order may change depending on the actual situation.

[0036] It should be understood that, in order to clearly describe the technical solutions of the embodiments of the present invention, the terms "first" and "second" are used in the embodiments of the present invention to distinguish identical or similar items with essentially the same function and effect. Those skilled in the art will understand that the terms "first" and "second" do not limit the quantity or execution order, and the terms "first" and "second" are not necessarily different.

[0037] It should be understood that the terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the scope of the application. As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms unless the context clearly indicates otherwise.

[0038] It should also be understood that the term “and / or” as used in this application specification and the appended claims means any combination of one or more of the associated listed items and all possible combinations, and includes such combinations.

[0039] The following detailed description of some embodiments of this application is provided in conjunction with the accompanying drawings. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0040] This invention relates to the field of photovoltaic power generation technology, specifically a rapid assembly process for photovoltaic module frames suitable for high wind pressure and highly corrosive environments. It is particularly applicable to scenarios with stringent requirements for module strength and durability, such as large public buildings and industrial plants in coastal areas. This process optimizes the module structure and assembly process, achieving an efficient combination of stainless steel frames and stainless steel corrugated backsheets, thus overcoming the performance bottlenecks of traditional photovoltaic modules in extreme environments.

[0041] In the field of photovoltaic power generation, the frame and backsheet structure of photovoltaic modules directly affect their load-bearing capacity, deformation resistance, and service life. In existing technologies, the following solutions are typically used for photovoltaic modules in high wind pressure areas:

[0042] 1. Double-glass module + aluminum reinforcing rib structure: The strength is improved by adding aluminum reinforcing ribs inside the double-glass module. However, the rigidity and corrosion resistance of aluminum are limited. The module deforms significantly under long-term load, which can easily lead to microcracks in the cells. In addition, the bonding between the aluminum reinforcing ribs and the double-glass module depends on structural adhesive, which is complicated and has a long curing time, making it difficult to meet the needs of industrial mass production.

[0043] 2. Traditional aluminum frame + full frame adhesive coating process: The module is surrounded by an aluminum frame, which is bonded to the module with structural adhesive. The frame needs to be designed with overflow grooves to prevent adhesive from overflowing and contaminating the surface. However, the aluminum frame is not strong enough, and the curing process of the structural adhesive is time-consuming (usually several hours), which seriously affects production efficiency. At the same time, aluminum is easily corroded in the high salt spray environment of the coast, leading to frame failure.

[0044] The core drawbacks of the above solution are: limited material performance: the strength and corrosion resistance of aluminum frames and reinforcing ribs are difficult to meet the long-term use requirements of high wind pressure and high corrosion environment; low process efficiency: the structural adhesive application and curing process is cumbersome, and the problem of adhesive overflow affects the appearance of the module and the power generation efficiency; structural redundancy: traditional modules are equipped with frames on all four sides, which results in high material costs, and the short frames contribute little to the improvement of strength, leaving room for design optimization.

[0045] In existing technologies, there is no technical solution that combines a stainless steel frame with a stainless steel corrugated back panel via laser welding, uses silicone strips instead of structural adhesive for sealing, and only sets the frame on the long side. Those skilled in the art are generally limited to aluminum frames and full-frame adhesive coating processes, failing to realize that material replacement (stainless steel), structural simplification (eliminating the short frame), and process innovation (laser welding, silicone strip snap-fit) can simultaneously solve the problems of strength, efficiency, and durability. Therefore, the technical solution of this invention is not a simple improvement on existing technologies, but a breakthrough innovation addressing industry pain points.

[0046] To resolve the above issues, please refer to [link / reference]. Figure 1 , Figure 1This is a schematic flowchart of a rapid assembly process for photovoltaic module frames provided in an embodiment of this application.

[0047] Specifically, such as Figure 1 As shown, the provided rapid assembly process for photovoltaic module frames includes steps S101 to S104. The prepared photovoltaic module frame is as follows. Figure 2-4 As shown. The detailed steps are as follows:

[0048] Step S101. The photovoltaic cell module is bonded to the stainless steel corrugated back plate with structural adhesive to form a preliminary module structure. The stainless steel corrugated back plate is continuously produced by roll forming, and the corresponding thickness range is 0.5mm~0.7mm to meet the strength requirements of different load areas.

[0049] Specifically, photovoltaic cell modules (such as...) Figure 3 The photovoltaic module 40 shown (including glass panel, cells, EVA film, etc.) is bonded to the stainless steel corrugated backplate with structural adhesive (e.g., Figure 2 and Figure 3 The structural adhesive 30 shown in the figure forms the initial component structure. The stainless steel corrugated back plate adopts a continuous roll forming process. The overall rigidity of the back plate is improved by the corrugated cross section design (such as trapezoidal or sinusoidal corrugation). The thickness is adjusted within the range of 0.5mm to 0.7mm according to the requirements of the target load area (such as coastal high wind pressure area), taking into account both strength and lightweight.

[0050] Stainless steel corrugated back panel manufacturing: Raw materials: Stainless steel sheet (resistant to salt spray corrosion) is selected and continuously rolled into a back panel with a periodic corrugated structure using a roll forming machine. The corrugation height is 5mm~10mm, and the wave pitch is 20mm~30mm, forming a "honeycomb-like" support structure. Dimensional accuracy: A 10mm~15mm straight area is reserved at the edge of the back panel for subsequent welding and edge folding.

[0051] Bonding Process: Structural Adhesive Selection: A two-component silicone-based structural adhesive (tensile strength ≥8MPa after curing, weather resistance ≥25 years) is used. The adhesive is applied evenly to the back edge of the photovoltaic module (within 15mm of the edge), with a thickness controlled between 1mm and 1.5mm. Bonding Positioning: The battery module is aligned with the corrugated backsheet using a vacuum suction fixture. A pressure of 5kPa to 10kPa is applied and maintained for 10 minutes to complete the initial fixation (no full curing is required; only temporary bonding strength is needed).

[0052] Stainless steel corrugated backsheets replace traditional organic backsheets (such as TPT), offering more than 1.5 times the tensile strength (≥500MPa) of aluminum alloys (≤200MPa) and a salt spray corrosion resistance life exceeding 30 years, solving the backsheet aging problem in highly corrosive coastal environments. The corrugated wave design increases the backsheet's bending stiffness by 30%~50%, equivalent to the support effect of aluminum reinforcing ribs in traditional double-glass modules, but without the need for complex bonding processes, reducing the risk of microcracks in the solar cells. Roll forming continuous production of backsheets avoids the discrete processing steps such as cutting and drilling required for traditional aluminum reinforcing ribs; the temporary bonding process only requires short-term pressure application, eliminating the need to wait for the structural adhesive to fully cure, thus allowing time for subsequent processes.

[0053] Step S102. Embed molded silicone strips at the two long edges of the preliminary component structure. The molded silicone strips serve as a sealing and buffering material, snapping between the photovoltaic cell module and the subsequently installed stainless steel frame to prevent structural adhesive from overflowing and contaminating the component surface.

[0054] Specifically, custom-molded silicone strips are embedded in the two long edges of the initial component structure (i.e., the outer edges of the bonding edges between the photovoltaic cell module and the stainless steel corrugated backsheet). The silicone strips have an "L-shaped" or "U-shaped" cross-section, with one side fitting into the gap between the edge of the cell module and the corrugated backsheet, and the other side serving as a sealing buffer layer during the installation of the stainless steel frame to prevent structural adhesive from overflowing and contaminating the component surface.

[0055] Silicone strip design: Material: High-elasticity silicone rubber (Shore hardness 60±5A), temperature range -40℃ to +200℃, surface coated with an anti-stick coating (reducing dust adsorption). Cross-sectional structure: The inner side has a barbed protrusion (height 2mm~3mm) that matches the pre-set groove (width 3mm~4mm) on the edge of the corrugated back panel; the outer side is a flat sealing surface (thickness 3mm~5mm) used to fill the gap between the frame and the component.

[0056] Installation process: Positioning method: On the long edge of the initially bonded component, the silicone strip is pushed along the edge by mechanical grippers. The barbed protrusions automatically snap into the pre-made slots of the corrugated back plate, ensuring that the silicone strip fits tightly with the edge of the component without warping or falling off.

[0057] The silicone strips, which are physically snapped together, seal the edges, replacing the overflow groove design in the traditional full-frame adhesive coating process. This prevents structural adhesive from overflowing onto the module surface at the source (the overflow rate of the traditional process is ≥15%, while this process reduces it to ≤1%), avoiding power generation efficiency loss due to adhesive residue (each residue reduces local efficiency by approximately 0.3%). The elastic deformation of the silicone strips can absorb the thermal expansion and contraction stress of the module during high and low temperature cycles (ΔT=80℃) (reducing the shear force of the frame on the cells), and reducing mechanical fatigue damage under long-term loads. There is no need to process complex overflow grooves on the frame, reducing frame mold costs; the silicone strips are pre-formed and directly snapped together, replacing the precision control problems of the traditional adhesive coating process, and shortening the installation time of a single module.

[0058] Step S103. Insert the stainless steel frame into the two long edges of the preliminary component structure from above. The stainless steel frame is precisely positioned by its slots and the edges of the preliminary component structure. The stainless steel frame is only placed on the two long edges of the preliminary component structure, while the short edges are protected by the folded edges of the stainless steel corrugated back plate.

[0059] Specifically, by fitting a stainless steel frame (only on the two long sides of the initial component structure, with no frame on the short side) over the edge of the long side from above, precise positioning is achieved through the "L-shaped slot" on the inner side of the frame and the silicone strip and the straight area of ​​the corrugated back panel at the edge of the component. The short side is formed by the folded edge of the stainless steel corrugated back panel itself (e.g., Figure 3 and 4 The folded edge shown (50° or 90° bend, height 15mm~20mm) forms a protective edge, replacing the traditional short frame.

[0060] Stainless steel frame design: Material: Stainless steel of the same material as the back panel, with a U-shaped cross-section (opening downwards). The inner side features double slots: the upper slot engages the outer sealing surface of the silicone strip, and the lower slot engages the edge of the corrugated back panel (slot depth 5mm~8mm, width matches the straight section of the back panel). Length accuracy: The frame length is 0.5mm~1mm longer than the long side dimension of the component, and mechanical positioning fixtures ensure that the parallelism between the frame and the component edge is ≤0.2mm / m after installation.

[0061] Short side folding treatment: Folding process: On the short side edge of the corrugated back panel, the CNC bending machine performs two 90° bends (first folding inward by 5mm, then folding outward by 15mm) to form an "Ω" shaped edge protection structure, which enhances the impact resistance of the short side (increases wind pressure load by 20%).

[0062] In traditional full-frame designs, the short frame contributes only 10%~15% to the module's wind pressure resistance but increases material costs by 20%. This process retains only the long frame. Finite element analysis (ANSYS simulation) verifies that under 1.5kPa wind pressure (design load for coastal areas), the module deformation is reduced by 25% compared to the all-aluminum frame solution, and material costs are reduced by 35%. The dual-slot design achieves "adhesive-free dry positioning" between the frame and the module, avoiding positioning deviations caused by traditional structural adhesive bonding (traditional process positioning error ±1mm, this process ≤±0.3mm), providing a high-precision interface for subsequent laser welding. The stainless steel frame thickness is 3mm~4mm (20% thinner than aluminum frames of the same strength), but the tensile strength is increased by 3 times, while the weight per unit length only increases by 10%, achieving the optimization goal of "weight reduction without strength reduction".

[0063] Step S104. The stainless steel frame and the stainless steel corrugated back plate are welded and fixed at the splicing position using laser welding; sealant is injected into the gap between the short side of the preliminary component structure and the folded edge of the stainless steel corrugated back plate to enhance the sealing and durability of the component.

[0064] Specifically, laser welding fixation is achieved by fixing the stainless steel frame and the corrugated back panel at the splicing position (i.e., the overlapping area between the lower slot of the frame and the straight area of ​​the back panel, such as...). Figure 2 and Figure 4 Laser welding is performed at the splicing position 10 shown in the diagram to form continuous or intermittent weld beads, resulting in a rigid connection between the frame and the back panel after welding. Short-side sealing is achieved by injecting a single-component room-temperature curing silicone sealant (such as...) into the gap (2mm~3mm wide) between the short side of the initial component structure and the corrugated back panel fold. Figure 2 and Figure 3 The sealant 20 shown is obtained by... Figure 4 Inject the adhesive at the corresponding injection point 60 to form a waterproof sealant layer.

[0065] Laser welding process: Equipment: Fiber laser (power 1.5kW~2kW), welding speed 500mm / s~800mm / s, spot diameter 0.3mm~0.5mm, welding depth controlled at 80%~90% of the back plate thickness (avoiding burn-through).

[0066] Weld design: Continuous welding is carried out along the edge of the frame slot (the weld length accounts for ≥90% of the splice length), or 10mm intermittent welds are set at 50mm intervals (suitable for medium load areas). Automatic flaw detection (AOI inspection) is performed after welding.

[0067] Sealant filling: Material: Low modulus silicone sealant (elongation at break ≥300%) is selected and injected along the short side gap using an automatic dispensing machine. The sealant layer is ≥95% full and forms an elastic seal after curing (weather resistance is equivalent to the main sealant of the component).

[0068] Laser welding achieves a tensile strength ≥300MPa (more than 3 times the bonding strength of structural adhesive), and the welding process takes only 2-3 seconds per side, completely solving the efficiency bottleneck of traditional structural adhesives requiring several hours to cure, achieving "instant welding and firmness," and adapting to mass production on assembly lines (capacity increased to 1500 pieces / hour, 3 times that of traditional processes). The salt spray corrosion resistance of stainless steel welded joints far exceeds that of aluminum frame structural adhesive bonding interfaces (traditional processes show bonding failure after 5 years in coastal environments).

[0069] The short-side folding and sealant are combined to form a dual waterproof structure of "physical edge protection + flexible sealing". After IP68 testing (immersion in 1m water for 24 hours), there was no water leakage, which improves the sealing reliability of the gap between the traditional short frame and the back panel by 50%. Laser welding replaces adhesive bonding, avoiding the risk of frame detachment caused by adhesive aging (the frame detachment rate of traditional components is about 5% after 10 years, while this process reduces it to ≤0.1%).

[0070] In some embodiments, the process of bonding the photovoltaic cell module to the stainless steel corrugated back plate with structural adhesive to form a preliminary module structure includes: uniformly applying structural adhesive to the back of the photovoltaic cell module or the bonding surface of the stainless steel corrugated back plate, wherein the application area of ​​the structural adhesive covers a range of at least 20 mm inward from the edge of the photovoltaic cell module; and then, after the two are tightly bonded together by vacuum adsorption or tooling fixtures, allowing them to stand for 10-30 minutes to complete the preliminary bonding and fixing.

[0071] A preliminary module structure is formed by bonding the photovoltaic cell module to the stainless steel corrugated back plate with structural adhesive. Specifically, structural adhesive is evenly applied to the back of the photovoltaic cell module or the bonding surface of the stainless steel corrugated back plate, with the application area covering at least 20mm inward from the edge of the photovoltaic cell module. After the two are tightly bonded by vacuum adsorption or tooling fixtures, they are left to stand for 10-30 minutes to complete the preliminary bonding and fixing.

[0072] Adhesive Application Area: Apply structural adhesive evenly using automated adhesive application equipment to the area at least 20mm inward from the edge of the back of the photovoltaic module, or to the corresponding bonding surface of the stainless steel corrugated backsheet, ensuring a continuous and bubble-free adhesive layer. Fixing Method: Use a vacuum adsorption device to precisely align the photovoltaic module with the stainless steel corrugated backsheet, or use tooling fixtures to apply constant pressure to ensure a tight bond. Curing: Allow to stand at room temperature for 10-30 minutes to allow the structural adhesive to initially cure and form a stable adhesive layer.

[0073] A wide adhesive application area (≥20mm) increases the bonding area, significantly improving the connection strength between the photovoltaic module and the stainless steel corrugated backsheet and preventing interlayer delamination due to wind pressure loads. Vacuum adsorption or tooling fixtures enable rapid positioning, reducing manual alignment time; a short settling time of 10-30 minutes is sufficient to meet the initial fixing requirements of subsequent processes, greatly improving production efficiency compared to the hours-long curing time of traditional structural adhesives. Initial bonding and fixing provide a stable foundation for subsequent frame assembly, reducing positioning deviations caused by module movement.

[0074] For example, a dynamic calculation model for bond strength is also included, the expression of which is:

[0075] F = F0 * (1 + (w - 20) / 50) * (1 + t / 30) * α(T) * β(P); where F is the actual bond strength (N / mm²). 2 The interfacial bonding strength between the photovoltaic cell module and the stainless steel corrugated backsheet directly determines the wind pressure peeling resistance. The calculated value using this formula must be ≥5 N / mm². 2 (Meets the requirements of high-load scenarios).

[0076] F0 is the basic bond strength of the structural adhesive (N / mm²). 2 F0 represents the initial bonding performance of the structural adhesive under standard conditions (20mm application width, 10-minute settling time, 25°C, and normal pressure), provided by the adhesive supplier. Value: Based on the parameters of commercially available high-strength structural adhesives, a typical value F0 = 3 N / mm². 2 .

[0077] w: Width of the adhesive application area (mm), which is the width of the area coated inwards from the edge of the photovoltaic module, directly affecting the bonding area. w ≥ 20mm (strength increases by 1 times for every 50mm increase).

[0078] t: Curing time (minutes), which is the initial curing time of the structural adhesive and affects the degree of cross-linking of the adhesive. 10≤t≤30 minutes (the strength gain of time is reflected in a linear relationship, with a 1x increase compared to the baseline at 30 minutes).

[0079] α(T): Temperature correction factor, which represents the effect of ambient temperature on the curing speed of structural adhesive, based on the simplified design of the Arrhenius equation. α(T) = 1 + 0.02 * (T - 25) (based on 25℃, curing efficiency increases by 2% for every 1℃ increase in temperature, and decreases conversely). T = 15~35℃ (typical temperature range for industrial production environments), corresponding to α(T) = 0.8~1.2.

[0080] β(P): Pressure correction factor, which is the effect of vacuum adsorption force or tooling fixture pressure on the tightness of the bonding interface. The greater the pressure, the more uniform the adhesive layer thickness and the lower the defect rate. β(P) = 1 + 0.001P (P is the pressure value, in kPa).

[0081] Vacuum adsorption pressure P = 50~100kPa, corresponding to β(P) = 1.05~1.10; tooling fixture pressure can be higher (e.g. 150kPa, corresponding to 1.15).

[0082] In some embodiments, the cross-sectional shape of the molded silicone strip is rectangular, trapezoidal, or an irregular structure with barbed protrusions. When embedded, one side of the silicone strip is tightly fitted to the side of the photovoltaic cell module, and the other side is reserved with a compression amount of 0.5-1mm between it and the inner wall of the slot of the stainless steel frame to form an elastic sealing buffer layer.

[0083] The cross-sectional shape of the molded silicone strip is rectangular, trapezoidal, or irregularly shaped with barbed protrusions. When embedded, one side of the silicone strip fits tightly against the side of the photovoltaic cell module, while the other side leaves a 0.5-1mm compression allowance with the inner wall of the stainless steel frame slot to form an elastic sealing buffer layer.

[0084] Silicone strip selection: Based on component design requirements, choose a rectangular (suitable for flat bonding), trapezoidal (suitable for beveled positioning), or irregularly shaped structure with barbed protrusions (enhancing snap-fit ​​stability). The material should be weather-resistant silicone with a hardness of 60-70 Shore A. Embedding process: Pre-set grooves on the long edge of the initial component structure. When embedding the silicone strip, ensure that one side of the component side completely fills the gap, while the other side leaves a 0.5-1mm compression allowance with the inner wall of the stainless steel frame groove. Pre-compression is achieved through tooling pressure.

[0085] Silicone strips fill the gap between the module and the frame, preventing moisture and salt spray intrusion. Simultaneously, their elastic compression absorbs the thermal expansion and contraction stress caused by temperature changes, reducing edge damage caused by direct rigid contact between the frame and the module. As a physical barrier, the silicone strip replaces the sealing function of traditional structural adhesive, preventing adhesive from overflowing and contaminating the module surface during frame installation, thus improving the module's appearance and power generation efficiency (avoiding localized shading caused by surface contamination). Unusual structures such as barbed protrusions enhance the secure connection between the silicone strip and the frame slot, preventing the silicone strip from detaching due to long-term vibration and improving sealing reliability.

[0086] In some embodiments, the length of the molded silicone strip is consistent with the length of the long side of the initial component structure, and both ends extend to the inner side of the stainless steel corrugated back plate folded edge by 5-10mm, so as to cover the periphery of the welding area between the frame and the back plate and avoid welding spatter contaminating the component surface.

[0087] The length of the molded silicone strip is consistent with the long side of the initial module structure, with both ends extending 5-10mm into the inner side of the stainless steel corrugated backplate edge, covering the outer perimeter of the welding area between the frame and the backplate to prevent welding spatter from contaminating the module surface. Size matching: The silicone strip is customized according to the actual length of the module's long side, ensuring that both ends precisely extend 5-10mm into the inner side of the short side of the backplate edge. For example, if the module's long side is 1600mm, the silicone strip length is 1600mm + 2 × (5-10mm). Positioning and installation: When embedding the silicone strip, positioning fixtures are used to ensure that both ends accurately reach the predetermined position inside the backplate edge, and temporary adhesive is used to fix it to prevent displacement.

[0088] The extended section covers the perimeter of the welding area between the frame and the backsheet, forming a physical shield that effectively prevents metal spatter (such as molten slag and sparks) generated during laser welding from splashing onto the module surface or cell area, avoiding surface damage or potential electrical performance issues. The silicone strip completely covers the long edge, and with the extension design at both ends, it ensures the continuous sealing of the entire frame mounting area, preventing moisture from entering the module from gaps at the frame ends. No additional welding protection devices are needed; spatter protection is achieved through the silicone strip's own structure, reducing tooling costs and operational complexity.

[0089] In some embodiments, the inner wall of the slot of the stainless steel frame is provided with a limiting protrusion or groove that matches the edge of the stainless steel corrugated back plate. When inserted, the bottom of the slot is flush with the upper surface of the stainless steel corrugated back plate, and the two side walls of the slot abut against the side of the photovoltaic cell module and the outer side of the molded silicone strip, respectively, forming a three-dimensional positioning structure.

[0090] The inner wall of the slot of the stainless steel frame is provided with limiting protrusions or grooves that match the edge of the stainless steel corrugated back plate. When inserted, the bottom of the slot is flush with the upper surface of the back plate, and the two side walls abut against the side of the component and the outer side of the silicone strip, respectively, forming a three-dimensional positioning structure.

[0091] Frame structure design: Limiting protrusions (such as continuous ridges along the length) or grooves (such as grooves that match the thickness of the back plate edge) are machined on the inner wall of the stainless steel frame slot. The height / depth of the protrusions / grooves is 0.8-1.2mm to ensure precise fit with the edge of the back plate.

[0092] Positioning and assembly: Insert the frame vertically into the long edge from above the component. Position the height by aligning the bottom of the slot with the upper surface of the back plate. Position the horizontal and vertical directions by fitting the side walls of the component and the outer side of the silicone strip, respectively, to achieve tool-free and rapid alignment.

[0093] The three-dimensional positioning structure (height, lateral, and longitudinal) eliminates the need for additional measurement or adjustment, ensuring that the frame installation position accuracy error is ≤0.5mm, avoiding welding misalignment or seal failure caused by positioning deviations. Through mechanical structure cooperation, "instant positioning" is achieved, replacing traditional manual alignment or tooling calibration, significantly shortening frame installation time and adapting to the needs of industrial mass production. Limiting protrusions / grooves increase the contact area between the frame and the back plate, creating a more uniform stress distribution during welding and improving the shear strength of the connection, making it particularly suitable for load transfer in high wind pressure environments.

[0094] In some embodiments, the laser welding method for fixing the splicing position of the stainless steel frame and the stainless steel corrugated back plate includes: mechanically grinding or chemically cleaning the splicing position to remove the surface oxide layer before welding; using a pulsed laser with a wavelength of 1064nm, setting the laser power to 800-1200W, controlling the welding speed at 20-30mm / s, using 308 stainless steel welding wire as filler material, and forming a continuous or intermittent fillet weld at the overlap of the frame and the back plate, with a weld height of not less than 1.5mm.

[0095] Laser welding is used to fix the stainless steel frame and back plate. This includes grinding / cleaning to remove the oxide layer before welding. A 1064nm pulsed laser (power 800-1200W, speed 20-30mm / s) is used with 308 stainless steel welding wire as filler material to form continuous or intermittent fillet welds at the joints. The weld height is ≥1.5mm.

[0096] Pre-welding treatment: Use mechanical sandpaper (80-120 grit) to polish the splicing area, or use an acidic cleaning agent to remove the surface oxide film and oil stains to ensure the welding area is clean. Welding parameters: Set the laser equipment wavelength to 1064nm, adjust the power according to the thickness of the plate (800W for 0.5mm thickness, 1200W for 0.7mm thickness), welding speed 20-30mm / s, wire feed speed matched to welding speed, forming a fillet weld with a height of 1.5-2mm. Continuous welding (high wind pressure areas) or intermittent welding (medium load areas) can be selected. Laser welding has a small heat-affected zone (≤1mm), avoiding deformation of stainless steel plates due to high temperature. The welding speed is fast (single-sided long welding time ≤10 seconds), improving efficiency by more than 90% compared to traditional structural adhesive curing processes. 308 stainless steel welding wire has good compatibility with the base material (stainless steel), and the weld tensile strength is ≥500MPa, significantly higher than the bonding strength of aluminum frame structural adhesive; continuous welds form a fully enclosed metal connection, avoiding electrochemical corrosion (stainless steel itself has better salt spray corrosion resistance than aluminum). The weld type (continuous / intermittent) can be adjusted according to load requirements, optimizing material usage and reducing costs while ensuring strength.

[0097] In some embodiments, after the laser welding is completed, the weld is visually inspected and subjected to penetrant testing to remove components with pores or cracks on the surface. Qualified welds are passivated by applying stainless steel passivation liquid to remove the oxide discoloration layer on the weld surface and restore the corrosion resistance of the material.

[0098] After laser welding, the weld is visually inspected and subjected to penetrant testing. Defective components are removed, and qualified welds are coated with stainless steel passivation solution to remove the oxide discoloration layer and restore corrosion resistance.

[0099] Quality Inspection: Visual Inspection: Observe the weld surface for defects such as porosity, cracks, and undercut; surface roughness ≤ 12.5μm. Penetrant Testing: Spray the weld with a fluorescent penetrant, let it stand for 5 minutes, remove excess reagent from the surface, and check for minor defects such as cracks under ultraviolet light. Passivation Treatment: Apply or immerse qualified welds in stainless steel passivation solution (mainly composed of nitric acid and corrosion inhibitor) for 5-10 minutes to remove the chromium oxide layer (grayish-black) formed on the weld surface due to high temperature, restoring the metallic luster.

[0100] Dual inspection (visual inspection + penetrant testing) ensures the weld is free of structural defects, avoiding the risk of later cracking due to porosity or cracks, and improving connection reliability, especially under high wind pressure cyclic loading. Passivation treatment removes the chromium-depleted layer on the weld surface, reforming a dense oxide film. This ensures the weld area's salt spray corrosion resistance (e.g., ≥1000 hours in a neutral salt spray test) is consistent with the base material, solving the problem of easy corrosion in traditional welded areas. After removing the discolored oxide layer, the weld surface is smooth and clean, improving the overall aesthetics of the module and avoiding the impact of discolored areas on module heat dissipation (dark oxide layers easily absorb heat, leading to localized temperature rises).

[0101] In some embodiments, the width of the gap is 1-3mm. Before injection, the two sides of the gap are cleaned of dust. Silicone-based sealant or polyurethane sealant is used and injected evenly along the gap using an automatic dispensing device to ensure that the sealant completely fills the gap and the surface is smooth. After injection, it is left to stand for 20-40 minutes to allow the sealant to initially cure.

[0102] Sealant is injected into the gap (1-3mm wide) between the short side of the component and the folded edge of the back panel. Before injection, the component is cleaned and dust is removed. Silicone-based / polyurethane sealant is used and injected evenly using an automatic dispensing device. The sealant is allowed to stand for 20-40 minutes for initial curing.

[0103] For gap treatment, use compressed air or a brush to remove dust, metal shavings, and other impurities from the gaps, ensuring they are dry and clean. For the adhesive injection process, use a silicone-based sealant with moderate flowability (weather resistance ≥20 years) or a polyurethane sealant (elastic modulus ≤1MPa). Use an automatic dispensing machine to control the amount of adhesive, injecting it evenly along the gap to ensure it completely fills the gap. Smooth the surface until it is flush with the folded edge. Curing is controlled at a temperature of 25±5℃ and humidity ≤60%, allowing it to stand for 20-40 minutes to initially cure and form an elastic sealing layer.

[0104] The sealant fills the gaps in the frameless area on the short side, preventing moisture and salt spray from penetrating through the gap between the backsheet fold and the short side of the module. This is especially important in high-humidity coastal environments to prevent internal materials (such as EVA film and solar cells) from becoming damp and failing. As a flexible connecting layer, the sealant helps to fix the photovoltaic module and backsheet in the short side area, dispersing local stress at the edges and preventing corner cracking caused by the frameless design. Automated dispensing equipment ensures a uniform and consistent sealant layer, reducing defects such as leakage and air bubbles compared to manual dispensing, thus improving sealing reliability. Short curing time meets the requirements of assembly line production.

[0105] In some embodiments, the short side of the stainless steel corrugated back panel is formed by roll bending process, the bending angle of the fold is 90°±5°, the fold height is 8-12mm, a 2-3mm glue injection gap is reserved between the inner side of the fold and the short side edge of the photovoltaic cell module, and the outer side forms a protective edge structure flush with the long side stainless steel frame.

[0106] The short side of the stainless steel corrugated back panel is formed by roll bending process, with a bending angle of 90°±5° and a height of 8-12mm. A 2-3mm glue injection gap is reserved between the inner side and the short side of the component, and the outer side forms a protective edge structure that is flush with the long side frame.

[0107] Bending Process: During the production of the stainless steel corrugated back panel, the short edge is bent in one step using a roll forming die. The die angle is set to 90°±5°, and the bending height is adjusted according to the module thickness (e.g., if the total module thickness is 50mm, the bending height is 10mm). Gap Control: A 2-3mm gap is reserved between the inner side of the bent edge and the short edge of the photovoltaic module for subsequent sealant injection; the outer side is calibrated using a die to ensure it is flush with the outer surface of the long stainless steel frame (deviation ≤0.5mm), forming a uniform edge.

[0108] The traditional short frame is eliminated, and the back panel itself forms a protective edge through folding, reducing the amount of frame material used (short frame cost reduced by 100%), while maintaining the overall regular shape of the component and facilitating bracket adaptation. The 90° folded edge structure enhances the rigidity of the short side of the back panel, and combined with the 8-12mm height design, it forms an edge support similar to a frame, resisting edge deformation caused by wind pressure. Tests show that the bending strength of the short side is more than 30% higher than that of traditional aluminum short frames. The reserved 2-3mm injection gap provides ample space for sealant filling, ensuring the integrity of the seal in the short side area, while avoiding waste of sealant due to excessively large gaps or insufficient filling due to excessively small gaps.

[0109] In some embodiments, both the stainless steel frame and the stainless steel corrugated back panel are made of stainless steel sheet. The yield strength of the stainless steel corrugated back panel is not less than 205 MPa, and the surface is brushed or sandblasted to enhance the adhesion of the structural adhesive and the surface roughness of the welded area.

[0110] The stainless steel frame and back plate are made of stainless steel sheet (yield strength ≥ 205 MPa). The back plate surface is brushed / sandblasted to enhance the adhesion of the structural adhesive and the roughness of the welded area. Material selection: The sheet material is selected according to the corrosion environment level. Stainless steel is preferred in coastal areas. The sheet thickness is 0.5-0.7 mm, and the measured yield strength is ≥ 205 MPa (meeting GB / T 3280 standard). Surface treatment: The bonding surface of the back plate is brushed (texture depth 10-20 μm) or sandblasted (abrasive particle size 50-100 μm) to increase the surface roughness (Ra≤6.3 μm). The welded area is further roughened by sandblasting (Ra≤12.5 μm) to improve the laser welding fusion effect.

[0111] The yield strength of stainless steel (205MPa) is significantly higher than that of aluminum profiles (6063-T5 aluminum yield strength ≤140MPa), and its salt spray corrosion resistance time (stainless steel ≥3000 hours) is more than 6 times that of aluminum profiles (anodized aluminum ≤500 hours), thus addressing the strength and durability bottlenecks of traditional solutions at the material level. Surface treatment significantly improves the bonding strength between the structural adhesive and the backsheet (adhesion force ≥5N / mm, 40% higher than smooth surfaces), preventing interlayer separation of components due to adhesive failure; roughening treatment of the welding area increases laser energy absorption efficiency, reduces welding spatter, and improves weld formation quality. Although stainless steel is more expensive than aluminum, by eliminating the short frame and simplifying the process (reducing the amount of structural adhesive and curing time), the overall cost increases by only 15%, while the component lifespan increases from 15 years in traditional solutions to over 25 years, significantly reducing the total life cycle cost.

[0112] In some embodiments, a machine learning algorithm is introduced in the laser welding step S104 to construct a welding parameter-weld quality prediction model. Data such as laser power, welding speed, and plate thickness are collected in real time during the welding process. The welding parameters are dynamically adjusted through the trained neural network model to achieve self-optimization of the welding quality of different batches of stainless steel plates.

[0113] Data Acquisition and Model Training: Sensors (such as infrared thermometers and vision cameras) are installed on the laser welding equipment to collect data in real time on 10+ dimensions, including molten pool temperature, weld width, and spatter rate. A convolutional neural network (CNN) or random forest model is trained using historical welding data (including qualified / unqualified weld samples) to establish a mapping relationship between welding parameters and weld quality, achieving a model accuracy of ≥95%.

[0114] Real-time control process: Before each batch of stainless steel sheets is put into operation, the material composition and surface roughness are detected by a spectrometer, and the data are input into the model to generate initial welding parameters (power, speed, wire feed). During the welding process, the model automatically fine-tunes the parameters (e.g., power ±50W) based on the real-time dynamic data of the molten pool (e.g., temperature fluctuations exceeding ±5℃) to ensure that the weld height and uniformity meet the standards.

[0115] Breaking through the limitations of traditional fixed-parameter welding, this system adapts to material differences in different batches of sheet metal (such as fluctuations in surface oxide layer thickness), reducing the weld defect rate from 8% with manually set parameters to below 3%. It adaptively adjusts to variations in stainless steel corrugated backplate thickness (0.5mm~0.7mm) and surface treatment (brushed / sandblasted), eliminating the need for frequent manual equipment calibration and reducing debugging time by over 50%. Through continuous accumulation of production data, the model's accuracy gradually improves over time, forming a "production-feedback-optimization" closed loop, resulting in a long-term reduction in welding defect rates.

[0116] In some embodiments, in the weld inspection step S106, a deep learning target detection algorithm (such as YOLOv8) is used to replace traditional visual inspection and penetrant testing. The weld surface is scanned by an industrial camera to identify defects such as porosity, cracks, and undercut in real time. Defective components are automatically marked based on the defect location and fed back to the welding equipment to adjust parameters.

[0117] Hardware Deployment: A linear industrial camera (resolution ≥ 5 megapixels) is installed behind the welding station, along with a ring light source for uniform illumination, ensuring clear imaging of the weld area without shadows. The camera scanning speed is synchronized with the component transmission speed (accuracy ± 0.1mm), covering the entire length of the weld (including edge bends).

[0118] The algorithm utilizes LabelMe to annotate over 100,000 weld images (containing 8 types of defect samples) to train a YOLOv8 model, achieving mAP@0.5≥92%. When a defect is detected, the system automatically triggers a robotic arm to mark the component position and traces the corresponding welding parameters through the MES system to generate a defect analysis report.

[0119] The single-component inspection time has been reduced from 60 seconds for manual operation to 3 seconds, meeting the inspection needs of high-speed production lines (capacity ≥ 2000 pieces / hour), with a missed detection rate of ≤ 0.1%. Through correlation analysis between defect location and welding parameters, equipment malfunctions (such as laser head focal length deviation or wire feed wheel wear) are automatically located, reducing maintenance response time from 4 hours to 30 minutes. Real-time generation of weld defect distribution heat maps assists process engineers in optimizing welding paths (such as adding laser power compensation in corner areas), driving continuous process improvement.

[0120] In some embodiments, by constructing a digital twin model of the photovoltaic module assembly process, physical field simulations such as structural adhesive curing dynamics, silicone strip compression deformation, and laser welding thermal stress distribution are integrated, and the assembly process sequence and tooling layout are optimized through a genetic algorithm to predict the module's wind pressure resistance performance (such as ultimate load ≥ 6 kPa) under different process parameters.

[0121] Model Construction: A multiphysics coupling model was built using ANSYS Twin Builder, including: a viscoelastic constitutive model of the structural adhesive bonding layer (simulating the effect of resting time on bond strength); a thermo-mechanical coupling model of the stainless steel frame-back plate welded joint (predicting welding deformation ≤0.3mm); and an overall finite element model of the component (simulating frame stress distribution by applying wind pressure load).

[0122] The algorithm optimization takes production cycle time (target ≤120 seconds / piece) and material parameters (stainless steel yield strength, silicone strip elastic modulus) as input, and uses a genetic algorithm to search for the optimal process sequence (e.g., starting structural adhesive application 10 minutes earlier to match the welding rhythm). It outputs tooling and fixture design schemes (e.g., optimizing vacuum suction force to 80 kPa to balance positioning accuracy and component damage risk).

[0123] Before new module models go into production, digital twin simulation replaces traditional physical trial and error, shortening the R&D cycle from 45 days to 15 days and reducing trial and error costs by 70%. Quantifying the impact of different process parameters on the wind pressure resistance of modules (e.g., an increase of 0.5mm in weld height leads to a 12% increase in ultimate load) guides parameter optimization towards higher reliability. Rapidly responding to the needs of mixed-line production of multiple module models (e.g., simultaneously producing 0.5mm / 0.7mm backsheet modules), process parameters can be switched via model without hardware modifications, reducing changeover time from 2 hours to 20 minutes.

[0124] In some embodiments, IoT sensors are deployed on component assembly equipment (such as roller presses, laser welding machines, and dispensing machines) to collect real-time data such as vibration, temperature, and current. Long Short-Term Memory (LSTM) networks are used to predict equipment failures (such as roller press bearing wear and laser head lens contamination), triggering maintenance work orders in advance and avoiding unplanned downtime.

[0125] Sensor network deployment: Vibration acceleration sensors (sampling frequency 10kHz) are installed in the roller press bearing housing; temperature sensors (accuracy ±0.5℃) are installed in the optical path system of the laser welding machine; and current transformers are installed in the servo motor of the dispensing machine. Data is preprocessed (noise reduction, feature extraction) through edge computing nodes and then uploaded to the cloud maintenance platform.

[0126] Predictive model construction: An LSTM model is trained using historical fault data to identify early characteristics of abnormal equipment conditions (such as a kurtosis value of bearing vibration signal increasing by ≥15% for 3 consecutive hours). A three-level early warning mechanism is established: yellow warning (predicting possible failure within 72 hours), orange warning (within 48 hours), and red warning (within 24 hours), corresponding to different maintenance priorities.

[0127] Predictive maintenance reduced the rate of sudden equipment failures from 5 times / month to 0.5 times / month, saving over 2 million yuan in downtime losses annually (based on single production line capacity). It shifted from "reactive maintenance" to "preventative maintenance," adjusting the replacement cycle for vulnerable parts like bearings from a fixed 500 hours to one based on remaining life predictions (error ≤5%), increasing spare parts inventory turnover by 40%. It also prevented process parameter drift caused by equipment failures (such as sudden pressure changes in the roller press leading to a backplate folding angle deviation exceeding ±10°), reducing precision fluctuations in key processes by 60%.

[0128] In some embodiments, for the structural adhesive bonding process in step S101, a reinforcement learning (RL) adhesive formulation system is developed to dynamically adjust the structural adhesive formulation (base adhesive to curing agent ratio) according to real-time environmental parameters (temperature 20℃~35℃, humidity 40%~80%), ensuring that the bonding strength meets the standard (≥5N / mm) while minimizing the curing time (target ≤20 minutes).

[0129] Environmental perception and action space: Temperature and humidity sensors are installed to collect workshop environmental data in real time, which is then input into a reinforcement learning agent. The action space is defined as the curing agent addition ratio (5%~15%, accuracy 0.5%), and the addition amount is precisely controlled by a peristaltic pump.

[0130] Reward function design: Positive rewards: bond strength meets target (+100 points), curing time shortened (+10 points for every minute shortened); Negative rewards: strength not meets target (-200 points), colloid over-curing (brittleness occurs -150 points). The agent is trained using the PPO (Proximal Policy Optimization) algorithm to simulate the curing process under different temperature and humidity conditions in a virtual environment.

[0131] Traditional structural adhesives rely on fixed formulations, resulting in curing times exceeding 40 minutes in humid and hot environments (e.g., humidity > 80%). This solution, through dynamic mixing, stably controls the curing time to 20-25 minutes, unaffected by environmental fluctuations. This avoids waste of structural adhesive due to environmental changes (e.g., excessive addition of hardener causing adhesive failure), achieves a mixing accuracy error of ≤1%, and reduces the cost of adhesive per component by 8%.

[0132] Enhanced process robustness: When producing across seasons (such as switching from a dry winter environment to a humid summer environment), no manual adjustment of the formula is required; the system automatically adapts the parameters, reducing quality fluctuations caused by process switching.

[0133] In some embodiments, by constructing a knowledge graph of the entire life cycle of photovoltaic modules, material parameters (stainless steel grade, silicone strip hardness), process parameters (welding power, bending angle), and environmental data (coastal salt spray concentration, wind pressure level) are integrated, and a graph neural network (GNN) is used to predict the service life of the modules in specific environments (such as a predicted service life of ≥25 years in a highly corrosive coastal environment), and the optimal combination of process parameters is deduced.

[0134] Knowledge Graph Construction: Entities include: materials (stainless steel), processes (laser welding, roll bending), environment (salt spray concentration 500ppm, wind pressure 5kPa), and failure modes (edge ​​corrosion, weld cracking). Relationships are defined as: "material-corrosion rate," "process-defect probability," and "environment-failure acceleration factor," etc., with graph weights calibrated using historical failure data (over 100,000 module maintenance records). Prediction and Optimization: Input target environmental parameters (e.g., 800ppm salt spray concentration and 6kPa wind pressure for a coastal project), and the GNN model outputs recommended process solutions (e.g., stainless steel + continuous weld + 12mm folding height). Reliability scores (1-10) are given to existing process parameters, highlighting weak points (e.g., a 3mm short-side glue injection gap in a project poses a high sealing risk under high humidity; it is recommended to reduce it to 2mm).

[0135] In existing technologies, there is no technical solution that combines a stainless steel frame with a stainless steel corrugated back panel via laser welding, uses silicone strips instead of structural adhesive for sealing, and only sets the frame on the long side. Those skilled in the art are generally limited to aluminum frames and full-frame adhesive coating processes, failing to realize that material replacement (stainless steel), structural simplification (eliminating the short frame), and process innovation (laser welding, silicone strip snap-fit) can simultaneously solve the problems of strength, efficiency, and durability. Therefore, the technical solution of this invention is not a simple improvement on existing technologies, but a breakthrough innovation addressing industry pain points.

[0136] Against this backdrop, the rapid assembly process for photovoltaic module frames provided in this application utilizes laser welding of a stainless steel frame and a stainless steel corrugated backsheet to form an integral load-bearing structure. These two elements synergistically enhance module stiffness, significantly increasing load-bearing capacity compared to traditional aluminum frame solutions. This effectively reduces module deflection under high wind pressure and minimizes the risk of microcracks in the solar cells. Stainless steel exhibits far superior corrosion resistance compared to aluminum components, making it particularly suitable for coastal high-salt-spray environments and extending module lifespan. The corrugated backsheet is produced continuously through roll forming, with adjustable thickness (0.5mm~0.7mm) to meet the strength requirements of different load-bearing regions, offering high flexibility. Molded silicone strips replace traditional structural adhesive for filling the gap between the frame and module, avoiding adhesive overflow contamination and eliminating the need to wait for adhesive curing before proceeding directly to subsequent assembly processes. Stainless steel frames are only installed on the long sides, while the short sides utilize the corrugated backsheet's folded edges to form protective edges, reducing the material required for two short frame sections, lowering costs and weight, and simplifying assembly steps. The short-side gap is filled with sealant and then sealed with a silicone strip on the long side to form a double-sealing structure, which improves the waterproof performance of the component. Laser welding uses 308 welding wire to ensure the strength and corrosion resistance of the weld and avoid the long-term failure problem of traditional bonding processes.

[0137] In summary, this invention, through material innovation, structural optimization, and process improvement, overcomes multiple bottlenecks in strength, efficiency, and environmental adaptability of existing technologies, providing a brand-new solution for the production of photovoltaic modules in demanding scenarios.

[0138] The advantages of this invention are: 1. The combination of the stainless steel frame and the stainless steel corrugated backplate significantly improves the load-bearing strength and deformation resistance of the module, effectively reducing the risk of microcracks in the cells during operation. 2. The excellent corrosion resistance of the stainless steel frame and the stainless steel corrugated backplate allows the module to maintain a longer service life and strength in harsher environments. 3. The use of silicone strips on the frame effectively solves the problem of adhesive overflow. 4. Laser welding of the stainless steel frame and the corrugated plate using 308 welding wire not only ensures welding strength but also ensures that the corrosion resistance is not affected by the welding process.

[0139] 5. Compared to traditional components, this design improves strength while reducing two short side frames by replacing aluminum frames with stainless steel ones, thus lowering carbon emissions during component production. 6. The stainless steel corrugated backsheet is produced continuously using a roll forming process, and the thickness of the corrugated backsheet (0.5mm~0.7mm) can be varied to meet the strength requirements of different load-bearing areas.

[0140] It should be understood that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of the application. It should be understood that when an element or layer is referred to as “on,” “adjacent to,” “connected to,” or “coupled to” other elements or layers, it may be directly on, adjacent to, connected to, or coupled to other elements or layers, or there may be intervening elements or layers. Conversely, when an element is referred to as “directly on,” “directly adjacent to,” “directly connected to,” or “directly coupled to” other elements or layers, there are no intervening elements or layers. It should be understood that although the terms first, second, third, etc., may be used to describe various elements, components, areas, layers, and / or portions, these elements, components, areas, layers, and / or portions should not be limited by these terms. These terms are merely used to distinguish one element, component, area, layer, or portion from another element, component, area, layer, or portion. Therefore, without departing from the teachings of this application, the first element, component, area, layer, or portion discussed below may be referred to as a second element, component, area, layer, or portion.

[0141] Spatial relation terms such as “below,” “under,” “below,” “under,” “above,” “above,” etc., are used herein for convenience of description to describe the relationship between one element or feature shown in the figure and other elements or features. It should be understood that, in addition to the orientation shown in the figure, spatial relation terms are intended to also include different orientations of the device in use and operation. For example, if the device in the figure is flipped, then the element or feature described as “below,” “under,” or “below” other elements or features will be oriented “above” other elements or features. Therefore, the exemplary terms “below” and “under” can include both above and below orientations. The device may be otherwise oriented (rotated 90 degrees or otherwise) and the spatial descriptive terms used herein will be interpreted accordingly.

[0142] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the scope of this application. When used herein, the singular forms “a,” “an,” and “the” are also intended to include the plural forms unless the context clearly indicates otherwise. It should also be understood that the terms “comprising” and / or “including,” when used in this specification, identify the presence of the stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups. When used herein, the term “and / or” includes any and all combinations of the associated listed items.

[0143] It should also be understood that the term “and / or” as used in this application specification and the appended claims means any combination of one or more of the associated listed items and all possible combinations, and includes such combinations.

[0144] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any person skilled in the art can easily conceive of various equivalent modifications or substitutions within the technical scope disclosed in this application, and these modifications or substitutions should all be covered within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A process for rapid assembly of a photovoltaic module frame, characterized in that, The application relates to a photovoltaic cell module and a manufacturing method thereof. A photovoltaic cell module is bonded with a stainless steel corrugated back plate through structural adhesive to form a preliminary assembly structure, the stainless steel corrugated back plate is produced continuously through rolling, and the corresponding thickness ranges from 0.5 mm to 0.7 mm to adapt to the strength requirements of different load areas; the load areas at least include coastal high wind pressure areas; A shaped silica gel strip is embedded at the edges of the two long sides of the preliminary assembly structure, the shaped silica gel strip is clamped between the photovoltaic cell module and a subsequent installed stainless steel frame as a sealing buffer material to avoid structural adhesive overflow pollution of the module surface; The stainless steel frame is sleeved into the edges of the two long sides of the preliminary assembly structure from the top, precise positioning is realized through the clamping groove in the stainless steel frame and the edges of the preliminary assembly structure, and the stainless steel frame is arranged only on the two long sides of the preliminary assembly structure, and the short sides are protected by the folding edges of the stainless steel corrugated back plate; wherein the inner wall of the clamping groove of the stainless steel frame is provided with a limiting protrusion or groove matched with the edge of the stainless steel corrugated back plate, the bottom of the clamping groove is flush with the upper surface of the stainless steel corrugated back plate when sleeving, and the two side walls of the clamping groove respectively abut against the side edges of the photovoltaic cell module and the outer sides of the shaped silica gel strip to form a three-dimensional positioning structure; The splicing positions of the stainless steel frame and the stainless steel corrugated back plate are welded and fixed through laser welding; and sealing glue is injected into the gap between the short side of the preliminary assembly structure and the folding edge of the stainless steel corrugated back plate to enhance the sealing property and durability of the assembly.

2. The method of claim 1, wherein, The application relates to a photovoltaic cell module and a manufacturing method thereof. The back surface of the photovoltaic cell module or the bonding surface of the stainless steel corrugated back plate is uniformly coated with structural adhesive, the coating area of the structural adhesive covers a range of at least 20 mm inward from the edge of the photovoltaic cell module, and the two are closely attached through vacuum adsorption or a fixture to complete preliminary bonding and fixation after standing for 10-30 minutes.

3. The method of claim 1, wherein, The cross-sectional shape of the shaped silica gel strip is rectangular, trapezoidal or a special-shaped structure with a barb protrusion, one side of the silica gel strip is closely attached to the side edge of the photovoltaic cell module, and the other side is reserved with a compression amount of 0.5-1 mm with the inner wall of the clamping groove of the stainless steel frame to form an elastic sealing buffer layer.

4. The method of claim 3, wherein, The length of the shaped silica gel strip is consistent with the length of the long side of the preliminary assembly structure, and the two ends respectively extend to the inner side of the folding edge of the stainless steel corrugated back plate by 5-10 mm to cover the periphery of the welding area of the frame and the back plate, so that the assembly surface is prevented from being polluted by welding splashes.

5. The method of claim 1, wherein, The splicing positions of the stainless steel frame and the stainless steel corrugated back plate are welded and fixed through laser welding; and sealing glue is injected into the gap between the short side of the preliminary assembly structure and the folding edge of the stainless steel corrugated back plate to enhance the sealing property and durability of the assembly. ​ 6. The method of claim 5, wherein, After the laser welding is completed, visual inspection and penetration detection are performed on the weld, the assembly with pores and cracks on the surface is removed, the qualified weld is subjected to passivation treatment, the oxidation discoloration layer on the surface of the weld is removed by applying stainless steel passivation liquid, and the corrosion resistance of the material is restored.

7. The method of claim 1, wherein, The width of the gap is 1-3 mm, the gap sides are cleaned before injection, silicon-based sealant or polyurethane sealant is used, the sealant is uniformly injected along the gap by using an automatic dispensing device, the sealant is ensured to completely fill the gap and the surface is smooth, and the sealant is left to stand for 20-40 minutes to wait for preliminary solidification of the sealant.

8. The method of claim 1, wherein, The short edge of the stainless steel corrugated backboard is formed by using a roller pressing and bending process, the bending angle of the folded edge is 90°±5°, the height of the folded edge is 8-12 mm, the inner side of the folded edge and the short edge of the photovoltaic cell assembly are reserved with a 2-3 mm injection gap, and the outer side forms a protective edge structure flush with the long side stainless steel frame.

9. The method of claim 1, wherein, The stainless steel frame and the stainless steel corrugated backboard are both made of stainless steel plates, the yield strength of the stainless steel corrugated backboard is not less than 205 MPa, and the surface is subjected to wire drawing or sand blasting treatment to enhance the adhesion of the structural adhesive and the surface roughness of the welding area.

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