Assembly type photovoltaic integrated module

Abstract

The invention relates to the technical field of photovoltaic integration, in particular to a fabricated photovoltaic integrated module which comprises a modular frame unit serving as a supporting body, a photovoltaic power generation unit fixed to the front face of the modular frame unit and a building function unit integrated to the back face of the modular frame unit. The unit integrates a mechanical interlocking mechanism, an integrated electric connector and a sealed drainage channel, and the mechanical interlocking mechanism realizes rapid alignment and preliminary locking through insertion matching of a convex connecting part and a concave connecting part which are arranged on the two sides of the module and can be finally fixed through a positioning pin; the integrated electric connector realizes plug-and-play electric communication between adjacent modules; and the sealing drainage channel forms a waterproof and water guide and drainage structure at the seam. Through factory prefabrication and integrated connection design, synchronous and rapid completion of on-site mechanical fixation, electrical communication and waterproof sealing is realized, and the construction efficiency, the connection reliability and the maintenance convenience are greatly improved.

Description

Technical Field

[0001] This invention relates to the field of photovoltaic integration technology, and specifically to a prefabricated photovoltaic integrated module. Background Technology

[0002] Building-integrated photovoltaics (BIPV) is a technology that integrates solar photovoltaic power generation products into buildings, and it is an important development direction for building energy conservation and green energy utilization.

[0003] Currently, most common photovoltaic building components are assembled on-site, where photovoltaic modules, insulation layers, waterproofing layers, and supporting structures are installed, spliced, and wired in stages on-site. This traditional method has the following problems: Low installation efficiency and long construction period: Each functional layer needs to be constructed on-site layer by layer, the process is complicated, the professional skills of the construction personnel are highly required, and it is greatly affected by the weather.

[0004] Poor connection reliability: Mechanical connections, electrical wiring and waterproof sealing are often handled separately, with many interfaces, which can easily lead to loose connections, poor contact or leakage due to poor construction quality.

[0005] Overall performance and lifespan matching issues: Different materials and components combined on-site may have mismatched coefficients of thermal expansion and durability, affecting the long-term stability and airtightness and watertightness of the overall structure.

[0006] Maintenance difficulties: When a fault occurs, it is difficult to quickly locate and replace specific functional units.

[0007] Therefore, there is an urgent need to provide a standardized photovoltaic building component that can be quickly assembled, reliably connected, stably performed, and easy to maintain. Summary of the Invention

[0008] To address the aforementioned technical problems, this invention provides a prefabricated photovoltaic integrated module. This module integrates the supporting structure, photovoltaic power generation, building envelope functions, and quick connection interfaces into one unit. It is prefabricated in the factory, allowing for simple on-site assembly to complete mechanical fixing, electrical connection, and waterproof sealing, thereby significantly improving construction efficiency, quality, and reliability.

[0009] It includes modular frame units, which constitute the supporting body of the module; A photovoltaic power generation unit is fixedly installed on the front side of the modular frame unit; Building functional units, integrated on the rear side of the modular frame unit, are used to provide the functions required by the building envelope; An integrated quick-connect unit is integrated on the side of the modular frame unit to enable rapid assembly between adjacent modules in terms of mechanical fixation, electrical connection and waterproof sealing.

[0010] Preferably, the modular frame unit includes a rectangular frame formed by four sets of the frame sides, each of the four sets of frame sides having an installation groove at its upper end, and horizontal and vertical reinforcing ribs fixedly connected between the four sets of frame sides by bolts. Each of the four sets of frame sides has an internal threaded hole at its upper end, and a limit installation unit can be detachably connected inside the internal threaded hole.

[0011] Preferably, the horizontal and vertical reinforcing ribs are arranged in a cross shape, and both ends of the four sets of frame sides are inclined at 45°. A first corner bracket connector and a second corner bracket connector are provided between two adjacent frame sides. The first corner bracket connector and the second corner bracket connector are fixedly connected to the two adjacent sets of frame sides by bolts, and a protective rubber pad is provided on the outside of the first corner bracket connector and the second corner bracket connector.

[0012] Preferably, the limiting installation unit includes a threaded rod threadedly connected inside the internal threaded hole and a rotating groove opened on the outer side of the upper end of the threaded rod. A limiting component is rotatably connected inside the rotating groove, and a limiting anti-slip pad is fixedly connected to the lower end of one side of the limiting component.

[0013] Preferably, the photovoltaic power generation unit includes a tempered glass layer, a photovoltaic cell layer, an EVA film layer, and a backsheet layer. The tempered glass layer is located on the front of the photovoltaic power generation unit, and the backsheet layer is located on the back of the photovoltaic power generation unit. The photovoltaic cell layer is composite and fixed to the tempered glass layer and the backsheet layer respectively through the EVA film layer. A buffer pad is provided between the backsheet layer and the horizontal and vertical reinforcing ribs.

[0014] Preferably, the building functional unit is a thermal insulation and waterproof composite layer, which includes a thermal insulation core material and a waterproof surface layer composited on its outer side. The thermal insulation core material is extruded polystyrene board or rigid polyurethane foam board, and the waterproof surface layer is TPO waterproof membrane. The extended edge of the waterproof surface layer is bonded and fixed to the outer wall of the rectangular frame by sealant.

[0015] Preferably, the integrated quick-connect unit includes A mechanical interlocking mechanism is provided on opposite sides of the modular frame unit to enable horizontal quick insertion of adjacent modules; An integrated electrical connector is located on the side of the modular frame unit and is electrically connected to the photovoltaic power generation unit to enable quick plug-in electrical connection between adjacent modules. Sealed drainage channels are formed at the joint surfaces of modular frame units to achieve waterproofing and drainage at the joints after the modules are assembled.

[0016] Preferably, the mechanical interlocking mechanism includes a convex connecting part and a concave connecting part respectively disposed on both sides of the modular frame unit, and the convex connecting part and the concave connecting part are interlocked by plugging.

[0017] Preferably, the convex connecting part is a trapezoidal tenon, and the concave connecting part is a trapezoidal mortise that matches the trapezoidal tenon. Both ends of the convex connecting part and the concave connecting part are provided with positioning holes. After the convex connecting part and the concave connecting part are inserted, the two coaxial positioning holes are fixed by positioning pins.

[0018] Preferably, it also includes a data monitoring unit, which is integrated inside the modular frame unit, for monitoring the module's operating status parameters and communicating through the data transmission line in the integrated electrical connector.

[0019] The technical effects and advantages of this invention are as follows: High integration and factory prefabrication: The structural frame, photovoltaic power generation unit, building functional layers and connection interfaces are integrated into a standard modular product, which is precision manufactured and tested in the factory, ensuring the consistency of product quality and performance.

[0020] Fast assembly and simple construction: With the integrated quick-connect unit on the side, during on-site installation, you only need to align the mechanical interlocking mechanism of the adjacent modules, plug in the electrical connectors, and ensure the seal is aligned to simultaneously complete the structural fixation, electrical series connection and initial waterproof sealing, which greatly simplifies the on-site operation process and reduces the technical dependence on construction personnel.

[0021] Reliable connection and superior performance: The mechanical interlock design ensures the strength and precision of the structural connection; the pre-integrated waterproof electrical connector avoids on-site wiring errors and poor contact; the specially designed sealed drainage channel realizes drainage as the main function at the joint, combined with prevention and drainage, and the waterproof sealing performance is reliable; the buffer pad between the back panel and the frame and the flexible connection of the building functional unit can effectively absorb and digest the temperature difference deformation stress.

[0022] Easy to maintain and replace: The modules adopt a standardized design. If a single module fails, the faulty module can be quickly replaced by removing the positioning pin, pulling out the electrical connector, and separating the mechanical lock, minimizing the impact on the overall system. The integrated data monitoring unit facilitates remote location of the fault point.

[0023] Fully functional and highly applicable: The module itself has complete functions of power generation, heat preservation, waterproofing and structural support. It can be directly used as the building envelope such as the exterior wall and roof, realizing true building-integrated photovoltaics. It is widely used in various new or renovated green building projects. Attached Figure Description

[0024] Figure 1 This application provides an embodiment of an explosion of a prefabricated photovoltaic integrated module. Figure 1 ; Figure 2This application provides an embodiment of an explosion of a prefabricated photovoltaic integrated module. Figure 2 ; Figure 3 This is a structural schematic diagram of a prefabricated photovoltaic integrated module provided in an embodiment of this application; Figure 4 This is a schematic diagram of the splicing of multiple modules in a prefabricated photovoltaic integrated module provided in an embodiment of this application; Figure 5 This is a structural schematic diagram of a modular frame unit in a prefabricated photovoltaic integrated module provided in an embodiment of this application; Figure 6 This is a schematic diagram of the structure of a photovoltaic power generation unit in a prefabricated photovoltaic integrated module provided in an embodiment of this application; Figure 7 This is a schematic diagram of the structure of a limiting installation unit in a prefabricated photovoltaic integrated module provided in an embodiment of this application; Figure 8 This is a cross-sectional view of a limiting installation unit in a prefabricated photovoltaic integrated module provided in an embodiment of this application; In the picture: 1. Modular frame unit; 11. Frame; 12. Mounting groove; 13. First corner bracket connector; 14. Second corner bracket connector; 15. Internal threaded hole; 16. Horizontal and vertical reinforcing ribs; 2. Photovoltaic power generation unit; 21. Tempered glass layer; 22. Photovoltaic cell layer; 23. EVA film layer; 24. Back panel layer; 3. Building functional unit; 31. Thermal insulation core material; 32. Waterproof surface layer; 4. Limiting installation unit; 41. Threaded rod; 42. Rotating groove; 43. Limiting component; 44. Limiting pad; 5. Integrated quick connection unit; 51. Convex connection part; 52. Concave connection part; 53. Positioning hole; 6. Buffer pad. Detailed Implementation

[0025] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments. The embodiments of the present invention are given for illustrative and descriptive purposes only, and are not intended to be exhaustive or to limit the invention to the forms disclosed. Many modifications and variations will be apparent to those skilled in the art. The embodiments were chosen and described to better illustrate the principles and practical application of the invention, and to enable those skilled in the art to understand the invention and design various embodiments with various modifications suitable for a particular purpose. Example

[0026] Please see Figures 1-8 This embodiment provides a prefabricated photovoltaic integrated module, including... The module mainly consists of four parts: a modular frame unit 1 that serves as a supporting skeleton, a photovoltaic power generation unit 2 installed on the front of the modular frame unit 1 for generating electricity, a building function unit 3 integrated on the back of the modular frame unit 1 to provide building functions such as thermal insulation and waterproofing, and an integrated quick connection unit 5 set on the side of the modular frame unit 1 for realizing rapid assembly between modules.

[0027] The modular frame unit 1 is composed of a rectangular metal frame, such as aluminum alloy. The frame is assembled from four side frames 11 by corner connectors. Each side frame 11 has a mounting groove 12 on its upper edge, i.e., the side facing the photovoltaic power generation unit 2, for embedding the edge of the photovoltaic power generation unit 2. Both ends of the four side frames 11 are processed into 45° bevels and are fastened with bolts by the first corner bracket connector 13 and the second corner bracket connector 14 to form a strong right-angle connection. Protective rubber pads are attached to the outside of the corner brackets to protect the sealing layer. The frame is fixed with bolts to horizontal and vertical reinforcing ribs 16 arranged in a cross shape to enhance the overall rigidity and provide central support for the photovoltaic panel. Multiple internal threaded holes 15 are also provided at the upper end of the side frame 11.

[0028] The limiting installation unit 4 is detachably connected to the internal threaded hole 15. It includes a threaded rod 41 with a rotating groove 42 at the top. The limiting member 43 is rotatably connected in the rotating groove 42. The lower end of the short arm of the limiting member 43 is glued with a limiting anti-slip pad 44. When the module is installed on the main building structure, the limiting member 43 can be rotated to the horizontal and the threaded rod 41 can be tightened so that the limiting anti-slip pad 44 presses tightly against the photovoltaic power generation unit 2, thereby achieving rapid fixation of the photovoltaic power generation unit 2.

[0029] The photovoltaic power generation unit 2 adopts a lamination encapsulation process. From the front to the back, it consists of: a high-transmittance tempered glass layer 21 as the front cover, a photovoltaic cell layer 22 as the main power generation unit, two layers of EVA film 23 for bonding and encapsulation, and a back sheet layer 24 as the back sheet. The back sheet layer 24 is made of TPT or PET composite material. The entire power generation unit is fixed in the mounting groove 12 of the modular frame unit 1 by structural adhesive. Between the back sheet layer 24 and the horizontal and vertical reinforcing ribs 16 of the frame, an elastic buffer pad 6, such as a silicone pad, is also provided to absorb the stress caused by thermal expansion and contraction and prevent microcracks in the cells.

[0030] The building functional unit 3 is bonded to the back of the modular frame unit 1 by an adhesive. It is usually a thermal insulation and waterproof composite layer, including an inner thermal insulation core material 31 and an outer waterproof surface layer 32. The edge of the waterproof surface layer 32 extends outward and is pasted to the outer wall of the frame 11 by weather-resistant sealant to form a complete waterproof wrap.

[0031] The integrated quick-connect unit 5 is the core of the invention for achieving rapid assembly. It is integrated on a set of opposite sides of the modular frame unit 1.

[0032] Mechanical interlocking mechanism: A convex connecting part 51 is formed on the side of one side frame 11, and a matching concave connecting part 52 is formed on the side of the other side frame 11. The two ends of the convex and concave connecting parts are provided with coaxial positioning holes 53. During installation, the convex connecting part 51 of module A is horizontally inserted into the concave connecting part 52 of the adjacent module B to achieve initial positioning and locking. Then, the positioning pin (not shown in the figure) is passed through the aligned positioning hole 53 to achieve final mechanical fixation and prevent the module from detaching.

[0033] Integrated electrical connector: Waterproof male and female mating electrical connectors are pre-installed inside the side of the frame 11, which is equipped with a mechanical interlocking mechanism. The connectors are directly connected to the output cables of the photovoltaic power generation unit 2. When the two modules are mechanically inserted into place, the electrical connectors on their sides are also aligned and inserted at the same time to realize electrical series or parallel connection.

[0034] Sealed drainage channel: A groove structure is formed on the mating surfaces of the convex connecting part 51 and the concave connecting part 52. When the two are inserted, a physical water-blocking barrier is formed.

[0035] In addition, a miniature data monitoring unit can be integrated inside the module to monitor the module's voltage, current, temperature and other statuses. The monitoring data can be transmitted to the system monitoring terminal via a dedicated data line in the integrated electrical connector or via power line carrier.

[0036] When using this invention In the factory, all components are assembled into a complete, tested, integrated module.

[0037] On-site, the main building support system, such as the keel, is first installed in place.

[0038] The first module is hoisted to the designated position and fixed to the keel by bolts and other mounting parts through the through holes opened on the rectangular frame. After the installation position is determined, waterproof sealant is applied to the through holes.

[0039] The second module is hoisted so that its concave connecting part 52 on one side is aligned with the convex connecting part 51 of the first module, and then pushed horizontally to fully insert it. During this process, mechanical interlocking, electrical connector insertion, and waterproof sealing surface bonding are completed simultaneously.

[0040] Insert the locating pin to complete the permanent mechanical locking between the two modules.

[0041] Repeat the steps to install subsequent modules in sequence to form a complete wall or roof.

[0042] Finally, apply a layer of weather-resistant sealant to the exposed parts at the top of all module joints as an auxiliary seal, and connect the cables at the beginning and end of the system to the inverter.

[0043] In this solution, unless otherwise explicitly specified and limited, the terms "installation", "setting", "connection", "fixing", "screw connection", etc., should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections or electrical connections; they can refer to direct connections or indirect connections through an intermediate medium; they can refer to the internal connection of two components or the interaction between two components. Unless otherwise explicitly limited, those skilled in the art can understand the specific meaning of the above terms in this solution according to the specific circumstances.

[0044] In the description of this invention, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. 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. Therefore, they should not be construed as limitations on this invention.

[0045] Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of them. All other embodiments obtained by those skilled in the art and related fields based on the embodiments of the present invention without inventive effort should fall within the scope of protection of the present invention. Structures, devices, and operating methods not specifically described and explained in the present invention, unless otherwise specified or limited, shall be implemented according to conventional means in the art.

Claims

1. A fabricated photovoltaic integrated module, characterized by, It comprises a modular frame unit (1) which constitutes the support body of the module; A photovoltaic power generation unit (2) is fixedly installed on the front side of the modular frame unit (1); A building function unit (3) is integrated on the back side of the modular frame unit (1) and is used to provide the functions required by the building envelope; An integrated quick connection unit (5) is integrated on the side of the modular frame unit (1) and is used to realize the quick assembly of adjacent modules in mechanical fixation, electrical communication and waterproof sealing.

2. The assembled photovoltaic integrated module according to claim 1, characterized in that, The modular frame unit (1) comprises a rectangular frame surrounded by four groups of the edge frames (11), the upper ends of the four groups of the edge frames (11) are each provided with an installation slot (12), a horizontal and vertical reinforcing rib (16) is fixedly connected between the four groups of the edge frames (11) by bolts, the upper ends of the four groups of the edge frames (11) are each provided with an internally threaded hole (15), and the inside of the internally threaded hole (15) is detachably connected with a limiting installation unit (4).

3. The assembled photovoltaic integrated module according to claim 2, characterized in that, The horizontal and vertical reinforcing rib (16) is arranged in a cross shape, the two ends of the four groups of the edge frames (11) are each provided with a 45° inclined surface, first and second corner code connectors (13) and (14) are arranged between two adjacent edge frames (11), the first and second corner code connectors (13) and (14) are fixedly connected with the adjacent two groups of the edge frames (11) by bolts, and the outer sides of the first and second corner code connectors (13) and (14) are provided with protective rubber pads.

4. The assembled photovoltaic integrated module according to claim 2, characterized in that, The limiting installation unit (4) comprises a threaded rod (41) which is threadedly connected in the internally threaded hole (15), and a rotating groove (42) which is arranged on the outer side of the upper end of the threaded rod (41), a limiting piece (43) is rotatably connected in the inside of the rotating groove (42), and a limiting anti-skid pad (44) is fixedly connected to the lower end of one side of the limiting piece (43).

5. The assembled photovoltaic integrated module according to claim 1, wherein, The photovoltaic power generation unit (2) comprises a tempered glass layer (21), a photovoltaic cell piece layer (22), an EVA adhesive film layer (23) and a back plate layer (24), the tempered glass layer (21) is located on the front side of the photovoltaic power generation unit (2), the back plate layer (24) is located on the back side of the photovoltaic power generation unit (2), and the photovoltaic cell piece layer (22) is fixedly combined with the tempered glass layer (21) and the back plate layer (24) through the EVA adhesive film layer (23); a buffer pad (6) is arranged between the back plate layer (24) and the horizontal and vertical reinforcing rib (16).

6. The assembled photovoltaic integrated module according to claim 1, wherein, The building function unit (3) is a heat preservation and waterproof composite layer which comprises a heat preservation core material (31) and a waterproof surface layer (32) which is combined on the outer side of the heat preservation core material (31), the heat preservation core material (31) is an extruded polystyrene board or a polyurethane hard foam board, and the waterproof surface layer (32) is a TPO waterproof coiled material, and the extension edges of the waterproof surface layer (32) are fixedly bonded and connected with the outer side walls of the rectangular frame through sealing glue.

7. The assembled photovoltaic integrated module according to claim 1, wherein, The integrated quick connection unit (5) comprises A mechanical interlocking mechanism is arranged on the opposite sides of the modular frame unit (1) and is used to realize the horizontal quick insertion of adjacent modules; Integrated electrical connector, arranged on the side of the modular frame unit (1) and electrically connected with the photovoltaic power generation unit (2), for realizing quick plug-in electrical connection between adjacent modules; Sealed drainage channel, formed at the joint surface of the modular frame unit (1), for realizing waterproof and drainage at the joint after module splicing.

8. The assembled photovoltaic integrated module according to claim 7, characterized in that, The mechanical interlocking mechanism includes a convex connecting part (51) and a concave connecting part (52) arranged on both sides of the modular frame unit (1) respectively, and the convex connecting part (51) and the concave connecting part (52) are interlocked by plug-in connection.

9. The assembled photovoltaic integrated module according to claim 8, wherein, The convex connecting part (51) is a trapezoidal tenon, the concave connecting part (52) is a trapezoidal mortise matched with the trapezoidal tenon, and both ends of the convex connecting part (51) and the concave connecting part (52) are provided with positioning holes (53), and the two coaxial positioning holes (53) are fixed by a positioning pin after the convex connecting part (51) and the concave connecting part (52) are plugged in.

10. The assembled photovoltaic integrated module according to claim 7, wherein, It also includes a data monitoring unit integrated in the interior of the modular frame unit, for monitoring the working state parameters of the module, and communicating through the data transmission line in the integrated electrical connector.

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