Photovoltaic module frame and assembly structure
By designing an H-shaped photovoltaic module frame and setting stacking slots or avoidance gaps on it, the photovoltaic panels can be stacked crosswise, which solves the problem of low space utilization in traditional photovoltaic module frames during stacking and transportation, increases the loading capacity, and improves the self-cleaning ability.
Patent Information
- Application Number
- CN202511481134.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-10-16
- Publication Date
- 2025-11-18
AI Technical Summary
Traditional photovoltaic module frames cannot be effectively nested during stacking and transportation, resulting in large gaps between modules, which seriously occupies container space, limits the number of modules that can be loaded per unit volume, and traditional frames are prone to accumulating dust, affecting their self-cleaning ability.
A photovoltaic module frame with an H-shaped structure is designed, with stacking slots or avoidance gaps, allowing adjacent photovoltaic panels to be stacked crosswise when stacked back to back, thereby reducing the stacking thickness through cross-nesting stacking.
It significantly reduces the overall thickness of multiple stacked components, reducing the equivalent single-component transport thickness to nearly half of the original thickness, greatly increasing the number of components loaded per unit transport space, and improving self-cleaning capabilities.
Smart Images
Figure CN120979323A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present application relates to the technical field of photovoltaic modules, in particular to a photovoltaic module frame and an assembly structure. BACKGROUND
[0002] With the transformation of global energy structure towards clean and low-carbon, photovoltaic power generation, as an important part of renewable energy, has been rapidly developed in recent years. The large-scale application of photovoltaic modules has promoted the technological progress of each link in the industry chain, and the structural design of the modules plays a key role in improving power generation efficiency, reducing manufacturing cost and optimizing transportation and installation. In traditional photovoltaic systems, the standard rigid photovoltaic module frame usually adopts an aluminum alloy frame to mechanically protect and structurally reinforce the glass-encapsulated cell. Such frame is mostly symmetrical rectangular or U-shaped cross-section structure. Although this design can provide good bending resistance and installation compatibility, it has obvious defects in the process of stacking and transporting the modules: since the frame has a continuous protruding structure in the length and width directions, the adjacent modules cannot be effectively nested when stacked back-to-back, resulting in a large gap between the modules, and the overall stacking thickness is close to twice the thickness of a single module, which seriously occupies the container space and limits the number of modules loaded in a unit volume.
[0003] Therefore, under the background of lightweight modules gradually entering mainstream applications, there is an urgent need for a new type of photovoltaic module frame structure that can achieve efficient nested stacking of modules during transportation and storage through structural innovation without changing the existing installation habits and system compatibility, thereby significantly reducing the logistics space occupation per unit power and further significantly reducing transportation and storage costs. SUMMARY
[0004] The present application provides a photovoltaic module frame and an assembly structure, which can reduce the total thickness of multiple photovoltaic modules, thereby significantly increasing the number of modules loaded in a unit transportation space.
[0005] Embodiments of the present application can be implemented as follows: Embodiments of the present application provide a photovoltaic module frame, which comprises: for being arranged along the four-direction of the photovoltaic panel to the edge of the photovoltaic panel, the photovoltaic module frame is h-shaped structure, and the photovoltaic module frame is provided with a stacking slot or a avoiding notch, in the case of back-to-back stacking of adjacent two photovoltaic panels, the adjacent two photovoltaic module frames are cross-stacked through the stacking slot or the avoiding notch, so as to reduce the total thickness of the stacked photovoltaic panels.
[0006] Optionally, the photovoltaic module frame includes a first frame and a second frame. The first frame is arranged along the length direction of the photovoltaic panel, and the second frame is arranged along the width direction of the photovoltaic panel. The first frame is provided with a stacking slot. When two adjacent photovoltaic panels are stacked back to back, the second frame of one of the photovoltaic panels cooperates with the stacking slot of the first frame of the adjacent photovoltaic panel, and the first frames of the two adjacent photovoltaic panels are stacked crosswise.
[0007] Optionally, the photovoltaic module frame further includes a right-angle connecting plate. The first frame has a first connecting groove, and the second frame has a second connecting groove. The right-angle connecting plate engages with both the first connecting groove and the second connecting groove to connect the first frame and the second frame.
[0008] Optionally, both ends of the right-angle connecting plate are provided with hooks, which are set upwards and engage with the first connecting groove and the second connecting groove respectively.
[0009] Optionally, the photovoltaic module frame includes a first support plate and a second support plate, the first support plate and the second support plate are connected, the second support plate has an L-shaped structure, the second support plate and the first support plate together form an h-shaped structure, the top surface of the second support plate is a support surface, the support surface is connected to the edge of the bottom surface of the photovoltaic panel, the side of the first support plate is connected to the side of the photovoltaic panel, and a stacking space is formed between the first support plate and the second support plate. When two adjacent photovoltaic panels are stacked back to back, the first support plate or the second support plate of one of the photovoltaic panels is located in the stacking space of the adjacent photovoltaic panels, so that the frames of two adjacent photovoltaic modules are stacked crosswise.
[0010] Optionally, the photovoltaic module frame further includes a buckle, the buckle including an elastic snap-fit part and an installation part, the elastic snap-fit part and the installation part are connected, the installation part is used for threaded connection with the bracket beam, the first frame is provided with an installation slot, and the elastic snap-fit part is snapped into the installation slot.
[0011] Optionally, the photovoltaic module frame includes a first frame and a second frame. The first frame is arranged along the length direction of the photovoltaic panel, and the second frame is arranged along the width direction of the photovoltaic panel. Both the first frame and the second frame have clearance notches at their ends. When two adjacent photovoltaic panels are stacked back to back, the first frame or the second frame of one photovoltaic panel cooperates with the clearance notch of the second frame or the first frame of the adjacent photovoltaic panel, so that the first frames and the second frames of the two adjacent photovoltaic panels are stacked crosswise.
[0012] Optionally, the photovoltaic module frame further includes a connecting corner bracket. The first frame has a first connecting cavity, and the second frame has a second connecting cavity. The connecting corner bracket engages with both the first connecting cavity and the second connecting cavity to connect the first frame and the second frame.
[0013] Optionally, the photovoltaic module frame includes a first support plate and a second support plate, the first support plate and the second support plate are connected, the second support plate has an F-shaped structure, the second support plate and the first support plate together form an h-shaped structure, the top surface of the second support plate is a support surface, the support surface is connected to the edge of the bottom surface of the photovoltaic panel, the side of the first support plate is connected to the side of the photovoltaic panel, and when two adjacent photovoltaic panels are stacked back to back, the outer sides of the first support plate and the second support plate of two adjacent photovoltaic module frames are in contact.
[0014] Optionally, the photovoltaic module frame further includes a pressure block, which includes a first pressure plate and a second pressure plate. The first pressure plate and the second pressure plate are connected and have an L-shaped structure. The first pressure plate is used for threaded connection with the support beam. Both the first frame and the second frame are provided with connection holes, and the second pressure plate is threadedly connected to the connection holes.
[0015] This invention also provides an assembly structure, including at least two photovoltaic panels and a photovoltaic module frame; Each of the photovoltaic panels is provided with a photovoltaic module frame around its four sides, and the photovoltaic module frame is located at the edge of the photovoltaic panel.
[0016] The beneficial effects of the photovoltaic module frame and assembly structure of the present invention include, for example: The photovoltaic module frame is positioned along the perimeter of the photovoltaic panel, with an H-shaped structure. The frame includes stacking slots or clearance notches. When two adjacent photovoltaic panels are stacked back-to-back, the frames can be interlocked via these slots or notches, reducing the overall thickness of the stacked photovoltaic panel. In use, the H-shaped frame design and stacking slots / notches allow for interlocking and nesting of frames between adjacent panels when stacked back-to-back, effectively avoiding the large gaps that occur with traditional continuous symmetrical frame structures. This structure significantly reduces the overall thickness of stacked modules, reducing the equivalent single-module transport thickness to nearly half of its original thickness, thereby greatly increasing the number of modules that can be loaded per unit transport space.
[0017] The assembly structure includes at least two photovoltaic panels and photovoltaic module frames; each photovoltaic panel has a photovoltaic module frame on all four sides, with the photovoltaic module frame positioned at the edge of the photovoltaic panel. In use, by designing the photovoltaic module frame as an H-shaped structure and providing stacking slots or clearance notches on the frame, adjacent photovoltaic panels can be stacked back-to-back with their frames interlocking, effectively avoiding the large gaps generated during stacking in traditional continuous symmetrical frame structures. This structure significantly reduces the overall thickness of multiple stacked modules, reducing the equivalent single-module transport thickness to nearly half of the original thickness, thereby greatly increasing the number of modules loaded per unit transport space. Attached Figure Description
[0018] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of the present invention and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.
[0019] Figure 1 This is a first-view structural schematic diagram of the assembly structure provided in Embodiment 1; Figure 2 This is a second-view structural schematic diagram of the assembly structure provided in Embodiment 1. Figure 3 This is a first-view structural schematic diagram of the photovoltaic module frame provided in Embodiment 1; Figure 4 This is a structural schematic diagram of the photovoltaic module frame from a second perspective provided in Embodiment 1; Figure 5This is a third-view structural diagram of the assembly structure provided in Embodiment 1; Figure 6 This is a fourth-view structural schematic diagram of the assembly structure provided in Embodiment 1. Figure 7 This is a fifth-view structural schematic diagram of the assembly structure provided in Embodiment 1. Figure 8 This is a third-view structural schematic diagram of the photovoltaic module frame provided in Embodiment 1. Figure 9 This is a sixth-view structural schematic diagram of the assembly structure provided in Embodiment 1. Figure 10 This is a first-view structural schematic diagram of the assembly structure provided in Embodiment 2. Figure 11 This is a second-view structural schematic diagram of the assembly structure provided in Embodiment 2. Figure 12 This is a third-view structural diagram of the assembly structure provided in Embodiment 2; Figure 13 This is a fourth-view structural diagram of the assembly structure provided in Embodiment 2. Figure 14 This is a fifth-view structural diagram of the assembly structure provided in Embodiment 2.
[0020] Icons: 10-Photovoltaic panel; 20-Photovoltaic module frame; 21-First frame; 210-First connecting groove; 22-Second frame; 220-Second connecting groove; 201-Stacking slot; 202-Avoidance notch; 203-First support plate; 204-Second support plate; 205-Support surface; 206-Mounting slot; 30-Right-angle connecting plate; 40-Snap-on; 41-Elastic snap-fit part; 42-Mounting part; 421-First mounting plate; 422-Second mounting plate; 50-Connecting corner bracket; 60-Pressure block; 70-Gathering box. Detailed Implementation
[0021] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.
[0022] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.
[0023] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.
[0024] In the description of this invention, it should be noted that if terms such as "upper," "lower," "inner," or "outer" are used to indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship in which the product of this invention is usually placed, they are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.
[0025] Furthermore, the terms "first" and "second" are used only to distinguish descriptions and should not be interpreted as indicating or implying relative importance.
[0026] It should be noted that, where there is no conflict, the features in the embodiments of the present invention can be combined with each other.
[0027] Example 1 With the global energy structure transitioning towards cleaner and lower-carbon energy, photovoltaic (PV) power generation, as a crucial component of renewable energy, has experienced rapid development in recent years. The large-scale application of PV modules has driven technological advancements across the entire industry chain, with module structural design playing a key role in improving power generation efficiency, reducing manufacturing costs, and optimizing transportation and installation. In traditional PV systems, standard rigid PV module frames typically use aluminum alloy frames to mechanically protect and structurally reinforce the glass-encapsulated solar cells. These frames are often symmetrical rectangular or U-shaped cross-sections. While this design provides good bending resistance and installation compatibility, it has significant drawbacks during module stacking and transportation: because the frames are continuously convex in both length and width, effective nesting cannot be achieved when adjacent modules are stacked back-to-back, resulting in large gaps between modules. The overall stack thickness is nearly twice the thickness of a single module, severely occupying container space and limiting the number of modules that can be loaded per unit volume.
[0028] Existing technologies attempt to increase transport density by optimizing packaging methods, adjusting pallet layouts, or using foldable supports. However, these methods often require additional tooling or changes to existing installation processes, increasing operational complexity and associated costs. Furthermore, some improved frame structures attempt to reduce stacking gaps through localized thinning or chamfering designs, but due to the inherent characteristics of symmetrical continuous structures, significant space compression remains difficult to achieve. Simultaneously, traditional frames are typically higher than the glass surface, creating a "dam" effect that easily accumulates dust and affects the module's self-cleaning ability, potentially leading to power generation efficiency losses over long-term operation.
[0029] Therefore, with lightweight modules gradually entering mainstream applications, there is an urgent need for a new type of photovoltaic module frame structure that can achieve efficient nesting and stacking of modules during transportation and storage without changing existing installation habits and system compatibility, thereby significantly reducing the logistics space occupied per unit power and thus significantly reducing transportation and warehousing costs.
[0030] Please refer to Figures 1-9 This embodiment provides an assembly structure including a photovoltaic module frame 20 and at least two photovoltaic panels 10. Each photovoltaic panel 10 has a photovoltaic module frame 20 on all four sides, and the photovoltaic module frame 20 is located at the edge of the photovoltaic panel 10. This can effectively improve the aforementioned technical problems, reduce the total thickness of multiple photovoltaic modules stacked, and thus significantly increase the number of modules loaded per unit transport space.
[0031] Please refer to Figures 1-9 The photovoltaic module frame 20 provided in this embodiment has an h-shaped structure and is provided with a stacking slot 201. When two adjacent photovoltaic panels 10 are stacked back to back, the two adjacent photovoltaic module frames 20 are stacked crosswise through the stacking slot 201 to reduce the total thickness of the stacked photovoltaic panels 10.
[0032] Specifically, there are multiple photovoltaic panels 10, which can be stacked and then packed into a central container for transportation. The photovoltaic module frame 20 is arranged sequentially around the perimeter of the photovoltaic panel 10, thereby surrounding the edge of the photovoltaic panel 10.
[0033] In this embodiment, the photovoltaic module frame 20 includes a first frame 21 and a second frame 22. The first frame 21 is arranged along the length direction of the photovoltaic panel 10, and the second frame 22 is arranged along the width direction of the photovoltaic panel 10. The first frame 21 is provided with a stacking slot 201. When two adjacent photovoltaic panels 10 are stacked back to back, the second frame 22 of one photovoltaic panel 10 cooperates with the stacking slot 201 of the first frame 21 of the adjacent photovoltaic panel 10, and the first frames 21 of the two adjacent photovoltaic panels 10 are stacked crosswise. That is, the length of the first frame 21 is longer than the length of the second frame 22, the first frame 21 is the long frame, and the second frame 22 is the short frame. The first frame 21 and the second frame 22 are arranged adjacent to each other in sequence.
[0034] Specifically, both ends of the first frame 21 are provided with stacking slots 201, which penetrate the bottom surface of the first frame 21 and have their openings facing downwards. When two adjacent photovoltaic panels 10 are stacked back to back, the second frame 22 can be placed in the stacking slots 201, and then the first frame 21 and the second frame 22 are stacked crosswise.
[0035] In this embodiment, the end faces of the stacking slot 201 and the first frame 21 are spaced apart, and the ends of the first frame 21 are beveled at 45°. The ends of the second frame 22 are recessed towards each other, thereby forming a stacking notch at the ends of the second frame 22. The ends of the second frame 22 are also beveled at 45° to facilitate the connection between the first frame 21 and the second frame 22.
[0036] Specifically, the photovoltaic module frame 20 also includes a right-angle connecting plate 30. The first frame 21 has a first connecting groove 210, and the second frame 22 has a second connecting groove 220. The right-angle connecting plate 30 engages with both the first connecting groove 210 and the second connecting groove 220 to connect the first frame 21 and the second frame 22. Each end of the right-angle connecting plate 30 has a hook, which faces upwards and engages with the first connecting groove 210 and the second connecting groove 220, respectively. After the hooks of the right-angle connecting plate 30 are engaged with the first connecting groove 210 and the second connecting groove 220, they are then bonded and fixed using structural adhesive.
[0037] Furthermore, the first frame 21 and the second frame 22 are bonded and fixed to the photovoltaic panel 10 with structural adhesive.
[0038] It should be noted that the photovoltaic module frame 20 includes a first support plate 203 and a second support plate 204. The first support plate 203 and the second support plate 204 are connected. The second support plate 204 has an L-shaped structure. The second support plate 204 and the first support plate 203 together form an H-shaped structure. The top surface of the second support plate 204 is a support surface 205. The support surface 205 is connected to the edge of the bottom surface of the photovoltaic panel 10. The side surface of the first support plate 203 is connected to the side surface of the photovoltaic panel 10. A stacking space is formed between the first support plate 203 and the second support plate 204. When two adjacent photovoltaic panels 10 are stacked back to back, the first support plate 203 or the second support plate 204 of one of the photovoltaic panels 10 is located in the stacking space of the adjacent photovoltaic panels 10, so that the two adjacent photovoltaic module frames 20 are stacked crosswise.
[0039] Furthermore, the first support plate 203 is a straight plate structure, one end of the second support plate 204 is connected to the upper middle part of the side of the first support plate 203, the lower middle parts of the first support plate 203 and the second support plate 204 are arranged in parallel and are both perpendicular to the photovoltaic panel 10, the lower middle parts of the first support plate 203 and the second support plate 204 form a support leg structure, and the top surface of the first support plate 203 is flush with the top surface of the photovoltaic panel 10, thereby realizing the full-screen design of glass or transparent cover, and the first connecting groove 210 is provided on the support surface 205 of the second support plate 204.
[0040] That is, in this embodiment, both the first frame 21 and the second frame 22 include a first support plate 203 and a second support plate 204.
[0041] When two adjacent photovoltaic panels 10 are stacked back to back, the second frame 22 of one photovoltaic panel 10 can be inserted into the stacking slot 201 of the first frame 21 of the other photovoltaic panel 10. Then the first support plate 203 and the second support plate 204 of the first frame 21 are cross-stacked with the first support plate 203 and the second support plate 204 of the second frame 22, forming a state of incomplete overlap.
[0042] When two adjacent photovoltaic panels 10 are stacked back-to-back, the total length of the stacked photovoltaic panels 10 is the sum of the length of the photovoltaic panels 10 and the distance between the stacking slot 201 and the end face of the first frame 21. In this embodiment, the distance between the stacking slot 201 and the end face is 15mm-40mm. Specifically, the distance between the stacking slot 201 and the end face can be 15mm. In other embodiments, the distance between the stacking slot 201 and the end face can also be 20mm, 30mm, 35mm or 40mm, and is not specifically limited here.
[0043] When two adjacent photovoltaic panels 10 are stacked back to back, the total thickness of the stacked photovoltaic panels 10 is the sum of the thickness of the photovoltaic panels 10 and the height of the first frame 21. In this embodiment, the first support plate 203 and the second support plate 204 have the same height.
[0044] When two adjacent photovoltaic panels 10 are stacked back-to-back, the total width of the stacked photovoltaic panels 10 is the sum of the width of the photovoltaic panels 10 and the thickness of the first support plate 203 and the second support plate 204 of the first frame 21. In this embodiment, the thickness of the first support plate 203 and the second support plate 204 is the same, ranging from 1mm to 3mm. In this embodiment, the thickness of the first support plate 203 and the second support plate 204 is 1mm. In other embodiments, the thickness of the support plate and the second support plate 204 can be 2mm or 3mm, and no specific limitation is made here.
[0045] In this embodiment, the height of the stacking slot 201 of the first frame 21 is 15mm, and the overlap depth of the first frame 21 and the second frame 22 after stacking is 15mm.
[0046] In this embodiment, the total thickness of the two stacked photovoltaic panels 10 is 36mm. In the prior art, the total thickness of the two stacked photovoltaic panels 10 is 60mm. By using the photovoltaic module frame 20 provided in this embodiment, the thickness of the stacked photovoltaic panels 10 can be significantly reduced.
[0047] It should also be noted that the photovoltaic module frame 20 further includes a clip 40, which includes a resilient snap-fit part 41 and a mounting part 42. The resilient snap-fit part 41 and the mounting part 42 are connected, and the mounting part 42 is used for threaded connection with the support beam. The first frame 21 is provided with a mounting slot 206, in which the resilient snap-fit part 41 snaps into the mounting slot 206. The mounting slot 206 is a square slot structure, and there are four mounting slots 206, which are spaced apart in the middle of the first frame 21. The mounting part 42 includes a first mounting plate 421 and a second mounting plate 422, which are arranged vertically. The elastic snap-fit part 41 is an elastic card structure and is connected to the first mounting plate 421. The second mounting plate 422 has a through hole and a bolt inside to thread the second mounting plate 422 and the bracket beam. The elastic snap-fit part 41 is located between the first support plate 203 and the second support plate 204, and then snaps into the mounting slot 206 to lock the first frame 21, thereby completing the assembly.
[0048] Furthermore, the connection between the elastic snap-fit part 41 and the first mounting plate 421 is rounded, and the connection position is arc-shaped.
[0049] More specifically, the back of the photovoltaic panel 10 is provided with multiple junction boxes 70, which are arranged sequentially and at intervals along the width direction of the photovoltaic panel 10. In this embodiment, the number of junction boxes 70 is three. Each junction box 70 is 30mm wide, and after two adjacent photovoltaic panels 10 are stacked, the staggered distance between the junction boxes 70 of adjacent photovoltaic panels 10 is 2cm. In other embodiments, the number of junction boxes 70 may be increased or decreased, and no specific limitation is made here.
[0050] In summary, this invention provides a photovoltaic module frame 20 and its assembly structure. The photovoltaic module frame is positioned along the periphery of the photovoltaic panel 10 at its edge. The photovoltaic module frame 20 has an H-shaped structure and includes stacking slots 201 or clearance notches 202. When two adjacent photovoltaic panels 10 are stacked back-to-back, the adjacent photovoltaic module frames 20 can be cross-stacked through the stacking slots 201 or clearance notches 202, thereby reducing the total thickness of the stacked photovoltaic panel 10. In use, by designing the photovoltaic module frame 20 as an H-shaped structure and providing stacking slots 201 or clearance notches 202 on the frame, adjacent photovoltaic panels 10 can be cross-nested when stacked back-to-back, effectively avoiding the large gaps generated during stacking in traditional continuous symmetrical frame structures. This structure significantly reduces the overall thickness of multiple stacked modules, reducing the equivalent single-module transport thickness to nearly half of the original thickness, thereby greatly increasing the number of modules loaded per unit transport space.
[0051] The assembly structure includes at least two photovoltaic panels 10 and photovoltaic module frames 20. Each photovoltaic panel 10 has a photovoltaic module frame 20 on all four sides, and the photovoltaic module frame 20 is located at the edge of the photovoltaic panel 10. In use, by designing the photovoltaic module frame 20 as an H-shaped structure and setting stacking slots 201 or avoidance notches 202 on the frame, the frames of two adjacent photovoltaic panels 10 can be stacked in a cross-nesting manner when stacked back to back, effectively avoiding the large area gaps generated during the stacking process of traditional continuous symmetrical frame structures. This structure significantly reduces the overall thickness of multiple modules after stacking, and the equivalent single module transport thickness is reduced to nearly half of the original thickness, thereby greatly increasing the number of modules loaded per unit transport space.
[0052] In 40HQ container transportation scenarios, compared to the traditional component's loading capacity of approximately 0.42MW, the solution of this invention can achieve a loading capacity of 0.72–0.73MW, an increase of over 70%, while reducing logistics costs by approximately 40%. In domestic 17.5-meter flatbed truck transportation, it can improve load utilization by over 20% while maintaining safe stacking height. This resulting improvement in space utilization efficiency is particularly suitable for long-haul, high-freight markets such as Africa, South America, and Canada, as well as large-scale domestic land transportation scenarios, and has significant economic value.
[0053] Furthermore, the H-shaped frame structure achieves lightweight design while possessing excellent mechanical properties. Its bottom support section has a U-shaped tubular structure, which, under the same material usage and height conditions, exhibits superior bending stiffness compared to traditional square tubular structures. This allows for reduced material usage while ensuring mechanical load-bearing capacity, lowering frame manufacturing costs by approximately 10%. Simultaneously, this structure facilitates a "full-screen" design, where the top surface of the frame is flush with or no higher than the surface of the photovoltaic panel 10, reducing dust accumulation dead zones, enhancing rainwater self-cleaning capabilities, and contributing to an approximately 7% increase in module power generation efficiency over long-term operation.
[0054] Example 2 Please refer to Figures 10-14 This embodiment provides an assembly structure including a photovoltaic module frame 20 and at least two photovoltaic panels 10. Each photovoltaic panel 10 has a photovoltaic module frame 20 on all four sides, and the photovoltaic module frame 20 is located at the edge of the photovoltaic panel 10. Unlike Embodiment 1, the photovoltaic module frame 20 provided in this embodiment has an avoidance notch 202. When two adjacent photovoltaic panels 10 are stacked back to back, the two adjacent photovoltaic module frames 20 are cross-stacked through the avoidance notch 202 to reduce the total thickness of the stacked photovoltaic panels 10.
[0055] The photovoltaic module frame 20 includes a first frame 21 and a second frame 22. The first frame 21 is arranged along the length direction of the photovoltaic panel 10, and the second frame 22 is arranged along the width direction of the photovoltaic panel 10. Both the first frame 21 and the second frame 22 have clearance notches 202 at their ends. When two adjacent photovoltaic panels 10 are stacked back to back, the first frame 21 or the second frame 22 of one photovoltaic panel 10 mates with the clearance notch 202 of the second frame 22 or the first frame 21 of the adjacent photovoltaic panel 10, so that the first frame 21 and the second frame 22 of the two adjacent photovoltaic panels 10 are stacked in an overlapping manner. That is, the length of the first frame 21 is longer than the length of the second frame 22, the first frame 21 is the long frame, and the second frame 22 is the short frame, and the first frame 21 and the second frame 22 are arranged adjacent to each other.
[0056] In this embodiment, the photovoltaic module frame 20 also includes a connecting bracket 50. The first frame 21 is provided with a first connecting cavity, and the second frame 22 is provided with a second connecting cavity. The connecting bracket 50 engages with both the first connecting cavity and the second connecting cavity to connect the first frame 21 and the second frame 22.
[0057] Specifically, both ends of the first frame 21 and the second frame 22 are recessed inward toward each other, thereby forming a clearance notch 202. The opening of the clearance notch 202 is set downward. When two adjacent photovoltaic panels 10 are stacked back to back, the first frame 21 and the second frame 22 can be cross-stacked through the clearance notch 202.
[0058] In this embodiment, the ends of the first frame 21 and the second frame 22 are also beveled at 45° to facilitate the connection between the first frame 21 and the second frame 22.
[0059] It should be noted that the photovoltaic module frame 20 includes a first support plate 203 and a second support plate 204. The first support plate 203 and the second support plate 204 are connected. The second support plate 204 has an F-shaped structure. The second support plate 204 and the first support plate 203 together form an h-shaped structure. The top surface of the second support plate 204 is a support surface 205. The support surface 205 is connected to the edge of the bottom surface of the photovoltaic panel 10. The side surface of the first support plate 203 is connected to the side surface of the photovoltaic panel 10. When two adjacent photovoltaic panels 10 are stacked back to back, the outer surfaces of the first support plate 203 and the second support plate 204 of the two adjacent photovoltaic module frames 20 are in contact.
[0060] Specifically, the first support plate 203 is a straight plate structure, and the second support plate 204 includes two horizontal plates and one vertical plate. The two horizontal plates are arranged in parallel, and the vertical plate is connected to both horizontal plates to form an F-shaped structure. The ends of the two horizontal plates away from the vertical plate are connected to the upper middle part of the side of the first support plate 203. The first support plate 203 and the vertical plate are arranged in parallel and are both perpendicular to the photovoltaic panel 10. The vertical plates of the first support plate 203 and the second support plate 204 form a support leg structure. The top surface of the first support plate 203 is flush with the top surface of the photovoltaic panel 10, thereby realizing a full-screen design of glass or transparent cover. The support surface 205 is set on the top surface of the upper horizontal plate.
[0061] In this embodiment, a protrusion is provided on the side of the two horizontal plates that are close to each other, so that the connecting corner bracket 50 can be snapped into the first connecting cavity, thereby achieving a stable connection.
[0062] In this embodiment, the first border 21 and the second border 22 have the same structure. The length of the second border 22 is less than the length of the first border 21.
[0063] Furthermore, both the first frame 21 and the second frame 22 are bonded to the photovoltaic panel 10 with structural adhesive.
[0064] When two adjacent photovoltaic panels 10 are stacked back to back, the first frame 21 of the two adjacent photovoltaic panels 10 overlaps, and the second frame 22 of the two adjacent photovoltaic panels 10 also overlaps, forming a state of partial overlap. That is, the vertical plates of the first support plate 203 and the second support plate 204 of the two adjacent photovoltaic panels 10 are attached and stacked.
[0065] When two adjacent photovoltaic panels 10 are stacked back-to-back, the total length of the stacked photovoltaic panels 10 is the sum of the length of the photovoltaic panels 10 and the increase in length of the photovoltaic module frame 20 after the two photovoltaic panels 10 are stacked. In this embodiment, the increase in length of the photovoltaic module frame 20 after the two photovoltaic panels 10 are stacked is 15mm-40mm. Specifically, the distance between the stacking slot 201 and the end face can be 16mm. In other embodiments, the distance between the stacking slot 201 and the end face can also be 15mm, 20mm, 30mm, 35mm or 40mm, and is not specifically limited here.
[0066] When two adjacent photovoltaic panels 10 are stacked back-to-back, the total thickness of the stacked photovoltaic panels 10 is the sum of the thickness of the photovoltaic panels 10 and the increase in thickness of the photovoltaic module frame 20 after the two photovoltaic panels 10 are stacked. In this embodiment, the increase in thickness of the photovoltaic module frame 20 after the two photovoltaic panels 10 are stacked is 4mm-7mm. In this embodiment, the increase in thickness of the photovoltaic module frame 20 after the two photovoltaic panels 10 are stacked is 4mm. In other embodiments, the increase in thickness of the photovoltaic module frame 20 after the two photovoltaic panels 10 are stacked is 5mm, 6mm, or 7mm, and no specific limitation is made here.
[0067] When two adjacent photovoltaic panels 10 are stacked back-to-back, the total width of the stacked photovoltaic panels 10 is the sum of the width of the photovoltaic panel 10 and the increase in width of the photovoltaic module frame 20 after the two photovoltaic panels 10 are stacked. In this embodiment, the increase in width of the photovoltaic module frame 20 after the two photovoltaic panels 10 are stacked is 10mm-20mm. In this embodiment, the increase in width of the photovoltaic module frame 20 after the two photovoltaic panels 10 are stacked is 10mm. In other embodiments, the increase in width of the photovoltaic module frame 20 after the two photovoltaic panels 10 are stacked is 12mm, 15mm, or 20mm, and no specific limitation is made here.
[0068] Furthermore, the photovoltaic module frame 20 also includes a pressure block 60, which includes a first pressure plate and a second pressure plate. The first pressure plate and the second pressure plate are connected and have an L-shaped structure. The first pressure plate is used to be threadedly connected to the support beam. Both the first frame 21 and the second frame 22 are provided with connection holes, and the second pressure plate is threadedly connected to the connection holes.
[0069] Taking the 460 lightweight module as an example, the product dimensions are 1761x1133x30mm. The width of the h-pin of the photovoltaic module frame 20 is 10mm, the cavity depth is 24mm, the junction box 70 is placed in the middle, the front glass thickness is 1.6mm, the height of the junction box 70 is 16mm, and the width is 30mm. A 14mm deep and 3mm wide stacking slot 201 is cut into the first frame 21 at a distance of 20mm from the second frame 22, resulting in four symmetrical stacking slots 201. These correspond to the outer legs of the U-shaped structure of the first frame 21. On the other side, a 14mm deep and 3mm wide stacking slot 201 is cut into the side at a distance of 30mm from the second frame 22, resulting in four symmetrical stacking slots 201. These correspond to the inner legs of the first frame 21 structure (near the center of the module). Correspondingly, we also cut a 4mm wide and 15mm deep groove at the distance between the second frame 22 and the first frame 21, with a total of 4 grooves, corresponding to the 2 outer legs of the second frame 22. The inner leg of the second frame 22 is controlled by reducing its length to 1133mm – 20mm (width of the two first frame 21 frames) – 5mm (tolerance redundancy) = 1108mm, which can avoid all overlapping requirements.
[0070] By stacking the components together, the total thickness of the two components is reduced from 30+30=60mm to 38mm, resulting in an equivalent component thickness of 19mm. Placing this component product in a 40HQ high cube container, with 26 pallets of components and 58 pieces per pallet, totaling 15,080 pieces, represents a 60% increase compared to the current 936 pieces per component, resulting in a corresponding reduction in shipping costs of approximately 38%. Here, the total weight of the lightweight components is kept below 22 tons, which is still within the allowable weight range of the container.
[0071] Replacing the 460W lightweight modules with 520W products changes the module size to 1975x1133x30mm. Using the same 20mm offset placement, 24 trays can be placed, with 58 modules per tray, for a total of 1392 modules. This corresponds to a power rating of 0.72MW for 40HQ modules, a 72% increase compared to the 0.42MW loading capacity of the normal 460W modules. Consequently, the transportation cost is reduced by approximately 41.8%.
[0072] Replacing the 460W lightweight modules with 620W products, the module dimensions become 2381x1133x30mm. Maintaining a 1mm offset placement, and considering the junction box 70 is reduced from 16mm to 12mm, the interference from the junction box 70 can be ignored. This allows for 20 trays of 58 modules per tray, totaling 1160 modules, corresponding to a 40HQ power rating of 0.72MW. This represents a 71% increase in load capacity compared to the standard 0.42MW for 460W modules, resulting in a corresponding reduction in transportation costs of approximately 41%.
[0073] In addition, considering the 17.5-meter flatbed truck used for domestic transportation, the assembly structure provided in Embodiments 1 and 2 can increase the load capacity from the original 28 tons to 35 tons, a 20% increase. Furthermore, it reduces the stacking height of the components.
[0074] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.
Claims
1. A photovoltaic module frame, characterized in that, The photovoltaic module frame (20) is an h-shaped structure and is provided with a stacking slot (201) or a clearance notch (202) on the edge of the photovoltaic panel (10) along the four sides of the photovoltaic panel (10). When two adjacent photovoltaic panels (10) are stacked back to back, the two adjacent photovoltaic module frames (20) are cross-stacked through the stacking slot (201) or the clearance notch (202) to reduce the total thickness of the stacked photovoltaic panel (10).
2. The photovoltaic module frame according to claim 1, characterized in that, The photovoltaic module frame (20) includes a first frame (21) and a second frame (22). The first frame (21) is arranged along the length direction of the photovoltaic panel (10), and the second frame (22) is arranged along the width direction of the photovoltaic panel (10). The first frame (21) is provided with a stacking slot (201). When two adjacent photovoltaic panels (10) are stacked back to back, the second frame (22) of one of the photovoltaic panels (10) cooperates with the stacking slot (201) of the first frame (21) of the adjacent photovoltaic panel (10), and the first frames (21) of the two adjacent photovoltaic panels (10) are stacked crosswise.
3. The photovoltaic module frame according to claim 2, characterized in that, The photovoltaic module frame (20) also includes a right-angle connecting plate (30). The first frame (21) is provided with a first connecting groove (210), and the second frame (22) is provided with a second connecting groove (220). The right-angle connecting plate (30) is simultaneously engaged with the first connecting groove (210) and the second connecting groove (220) to connect the first frame (21) and the second frame (22).
4. The photovoltaic module frame according to claim 3, characterized in that, Both ends of the right-angle connecting plate (30) are provided with hooks, which are set upwards and are respectively engaged with the first connecting groove (210) and the second connecting groove (220).
5. The photovoltaic module frame according to claim 1, characterized in that, The photovoltaic module frame (20) includes a first support plate (203) and a second support plate (204). The first support plate (203) and the second support plate (204) are connected. The second support plate (204) has an L-shaped structure. The second support plate (204) and the first support plate (203) together form an h-shaped structure. The top surface of the second support plate (204) is a support surface (205). The support surface (205) is connected to the edge of the bottom surface of the photovoltaic panel (10). The side of the first support plate (203) is connected to the side of the photovoltaic panel (10). A stacking space is formed between the first support plate (203) and the second support plate (204). When two adjacent photovoltaic panels (10) are stacked back to back, the first support plate (203) or the second support plate (204) of one of the photovoltaic panels (10) is located in the stacking space of the adjacent photovoltaic panels (10), so that the two adjacent photovoltaic module frames (20) are stacked crosswise.
6. The photovoltaic module frame according to claim 2, characterized in that, The photovoltaic module frame (20) also includes a buckle (40), the buckle (40) includes an elastic snap-fit part (41) and an installation part (42), the elastic snap-fit part (41) and the installation part (42) are connected, the installation part (42) is used to be threadedly connected to the support beam, the first frame (21) is provided with an installation slot (206), and the elastic snap-fit part (41) is snapped into the installation slot (206).
7. The photovoltaic module frame according to claim 1, characterized in that, The photovoltaic module frame (20) includes a first frame (21) and a second frame (22). The first frame (21) is arranged along the length direction of the photovoltaic panel (10), and the second frame (22) is arranged along the width direction of the photovoltaic panel (10). Both the first frame (21) and the second frame (22) are provided with clearance notches (202) at their ends. When two adjacent photovoltaic panels (10) are stacked back to back, the first frame (21) or the second frame (22) of one of the photovoltaic panels (10) cooperates with the clearance notch (202) of the second frame (22) or the first frame (21) of the adjacent photovoltaic panel (10), so that the first frame (21) and the second frame (22) of the two adjacent photovoltaic panels (10) are stacked crosswise.
8. The photovoltaic module frame according to claim 7, characterized in that, The photovoltaic module frame (20) also includes a connecting corner bracket (50). The first frame (21) is provided with a first connecting cavity, and the second frame (22) is provided with a second connecting cavity. The connecting corner bracket (50) is simultaneously engaged with the first connecting cavity and the second connecting cavity to connect the first frame (21) and the second frame (22).
9. The photovoltaic module frame according to claim 1, characterized in that, The photovoltaic module frame (20) includes a first support plate (203) and a second support plate (204). The first support plate (203) and the second support plate (204) are connected. The second support plate (204) has an F-shaped structure. The second support plate (204) and the first support plate (203) together form an h-shaped structure. The top surface of the second support plate (204) is a support surface (205). The support surface (205) is connected to the edge of the bottom surface of the photovoltaic panel (10). The side surface of the first support plate (203) is connected to the side surface of the photovoltaic panel (10). When two adjacent photovoltaic panels (10) are stacked back to back, the outer surfaces of the first support plate (203) and the second support plate (204) of the two adjacent photovoltaic module frames (20) are in contact.
10. The photovoltaic module frame according to claim 7, characterized in that, The photovoltaic module frame (20) also includes a pressure block (60), which includes a first pressure plate and a second pressure plate. The first pressure plate and the second pressure plate are connected and have an L-shaped structure. The first pressure plate is used to be threadedly connected to the support beam. The first frame (21) and the second frame (22) are both provided with connection holes. The second pressure plate is threadedly connected to the connection holes.
11. An assembly structure, characterized in that, include: At least two photovoltaic panels (10) and a photovoltaic module frame (20) as described in any one of claims 1-10; Each of the photovoltaic panels (10) is provided with a photovoltaic module frame (20) in all four directions, and the photovoltaic module frame (20) is provided at the edge of the photovoltaic panel (10).