Steel closed frame

Abstract

The invention discloses a steel closed type frame which is of an integrated structure formed by rolling steel for multiple times, and the steel closed type frame comprises a notch part with an open end, a closed part arranged below the notch part and a connecting arm extending out from the lower end of the closed part, and the extending direction of the connecting arm is consistent with the orientation of the opening end of the notch part. According to the steel closed frame, stable positive and negative load bearing capacity and torsion resistance can be formed through mutual supporting and coating of self structures, insufficient bearing capacity caused by separation and displacement of two layers of materials during bearing can be avoided, and bearing burst of glass assembly pieces can be reduced due to existence of a certain elastic space, so that the service life of the glass assembly pieces is prolonged, and the service life of the glass assembly pieces is prolonged. And meanwhile, the surface of the material is not easy to crack when the frame is formed by rolling.

Description

Technical Field

[0001] This invention relates to a support frame, and more particularly to a steel support frame. Background Technology

[0002] The photovoltaic (PV) frame is one of the important structural components of a PV module. It protects the glass edges, enhances the sealing performance of the PV module, and improves the overall mechanical strength of the module. The PV frame facilitates the installation, transportation, and operation of the PV module, and load-bearing is also one of its important functions. Currently, over 90% of PV frames are made of aluminum, with a smaller proportion made of steel or composite materials.

[0003] Compared to aluminum frames, steel frames offer higher strength, lower cost, and lower carbon emissions. However, unlike aluminum frames which are formed by extrusion, photovoltaic steel frames are mostly formed by roll forming of thin strips. Nevertheless, the strength of current steel frame structures is still insufficient to meet the demands of current products.

[0004] Existing patent literature already relates to photovoltaic steel frames, including:

[0005] For example, Chinese patent document CN116365986A, published on June 30, 2023, entitled "An Aluminum-Magnesium-Zinc Steel Frame for Photovoltaic Modules," discloses an aluminum-magnesium-zinc steel frame for photovoltaic modules. The beneficial effects of this Chinese patent document are to reduce the cost of manual removal and adhesive scraping, improve the installation firmness of photovoltaic modules, facilitate the transportation of photovoltaic modules, prevent the side slippage of photovoltaic modules, and facilitate automatic packaging operations. However, when the entire module panel is subjected to a positive load, the two layers of material in the slot are prone to separation and displacement, resulting in a weakened or even insufficient load-bearing capacity.

[0006] For example, Chinese patent document CN114844455A, published on August 2, 2022, entitled "High-strength steel cold-formed profile for photovoltaic module frame," discloses a high-strength steel cold-formed profile for photovoltaic module frame. This Chinese patent document avoids the separation and displacement of the two layers of materials when the module panel is subjected to positive load by welding between the two layers, thereby improving the load-bearing capacity of the frame. However, welding may cause a certain degree of surface damage, especially for uncoated bare parts, which may pose a challenge to the corrosion resistance of the frame module. Summary of the Invention

[0007] The purpose of this invention is to provide a steel closed frame that can form a stable load-bearing capacity through mutual support and covering of its own structure. This can avoid insufficient load-bearing capacity caused by the separation and displacement of the two layers of materials during load-bearing, and is also easy to form.

[0008] To achieve the above objectives, the present invention proposes a steel closed frame, which is an integral structure made of steel through multiple roll forming processes. The steel closed frame includes: a slotted portion with an open end, a closed portion disposed below the slotted portion, and a connecting arm extending from the lower end of the closed portion. The extension direction of the connecting arm is consistent with the orientation of the open end of the slotted portion.

[0009] In this invention, the slot is used for mounting the battery glass module; the closed part is a closed cavity structure and is the main load-bearing structure for the battery glass module; the connecting arm is mainly used for connecting with the photovoltaic bracket.

[0010] Furthermore, in the steel closed frame of the present invention, the slot portion includes a top, a slot sidewall, and a bottom shared with the closed portion. The top is inclined downward in a direction extending outward from the slot sidewall to form an angle α1 with the bottom.

[0011] Furthermore, in the steel closed frame described in this invention, the included angle α1 ranges from 4 to 10°.

[0012] In this implementation, when the included angle α1 is controlled between 4 and 10°, the load-bearing capacity of the glass assembly when it bears a load (i.e., an upward load) can be enhanced while ensuring a certain elastic space to prevent the glass assembly from bursting.

[0013] Furthermore, in the steel closed frame of the present invention, the outer edge of the top of the slot portion has at least three layers of steel.

[0014] Furthermore, in the steel closed frame of the present invention, the outer edge of the top of the slot portion has a closed edge structure, and the cross-section of the steel faces the side wall of the slot.

[0015] In this implementation, when the steel is rolled into the frame cross-section and a closed edge structure is formed at the top, the occurrence of material corrosion can be further reduced after the glass panels are installed.

[0016] Furthermore, in the steel closed frame of the present invention, a first rounded corner is provided between the top of the slot and the side wall of the slot. The first rounded corner has at least two layers of steel to form a first upper rounded corner and a first lower rounded corner, wherein the inner rounded corner radius of the first upper rounded corner is smaller than the outer rounded corner radius of the first lower rounded corner.

[0017] In this implementation, a two-layer rounded corner structure is formed by the design of the first upper rounded corner and the first lower rounded corner, and the two rounded corners are interference-fitted, with the upper layer of material tightly covering the lower layer of material, thereby making the structure more stable.

[0018] In this implementation, the load-bearing capacity of the glass assembly under negative loads (i.e., upward loads) can be further enhanced while ensuring a certain elastic space to prevent the glass assembly from cracking, and the two layers of material are not easily separated under load.

[0019] Furthermore, in the steel closed frame of the present invention, the outer radius of the first lower rounded corner R1 = k1 × t, where t represents the single layer thickness of the steel, and the value range of the first adjustment coefficient k1 is 1 to 2.

[0020] Furthermore, in the steel closed frame of the present invention, a second rounded corner is provided between the bottom of the slot and the side wall of the slot. The second rounded corner has at least two layers of steel to form a second upper rounded corner and a second lower rounded corner, wherein the inner rounded corner radius of the second lower rounded corner is smaller than the outer rounded corner radius of the second upper rounded corner.

[0021] In this embodiment, a two-layer rounded corner structure is formed by the second lower rounded corner and the second upper rounded corner, and the two rounded corners are interference-fitted, so that the lower layer of material tightly covers the upper layer of material, thereby making the structure more stable.

[0022] In this implementation, the design of the second upper rounded corner and the second lower rounded corner can significantly improve the load-bearing capacity of the glass assembly under positive loads (i.e., downward loads) while ensuring that the two layers of material do not separate.

[0023] Furthermore, in the steel closed frame of the present invention, the second lower rounded corner has a horizontal section extending toward the open end.

[0024] In this implementation, the lower layer of material extends inward into a horizontal section of width W, providing effective support for the upper layer of material.

[0025] Furthermore, in the steel closed frame of the present invention, the extension length W of the horizontal segment is W = k2 × t, where t represents the single layer thickness of the steel, and the value range of the second adjustment coefficient k2 is 3 to 5.

[0026] In this implementation, the extension length W helps to further significantly improve the load-bearing capacity of the glass assembly under positive loads (i.e., downward loads) while ensuring that the two layers of material do not separate.

[0027] Furthermore, in the steel closed frame of the present invention, the closed part includes an upper end, a first side wall, a second side wall and a lower end shared with the bottom of the slot part. The first side wall includes a first inclined part and the second side wall includes a second inclined part. Both the first inclined part and the second inclined part are inclined outward from top to bottom.

[0028] Furthermore, in the steel closed frame of the present invention, the included angle α2 between the first inclined portion and the lower end is 80 to 85°.

[0029] Furthermore, in the steel closed frame of the present invention, the included angle α3 between the second inclined part and the lower end is α2 + β, the value range of the adjustment angle β is 0 to 2°, and α2 is the included angle between the first inclined part and the lower end.

[0030] Furthermore, in the steel closed frame of the present invention, the first sidewall further includes a first vertical portion located below the first inclined portion, and the second sidewall further includes a second vertical portion located below the second inclined portion.

[0031] Furthermore, in the steel closed frame described in this invention, the first vertical portion and the second vertical portion have the same height.

[0032] Furthermore, in the steel closed frame of the present invention, the height H0 of the first vertical part and / or the second vertical part is k3×H1, where H1 represents the total height of the closed part, and the value range of the third adjustment coefficient k3 is 0.1 to 0.2.

[0033] Furthermore, in the steel closed frame of the present invention, the first vertical part and the slot sidewall are located on the same vertical plane.

[0034] In this embodiment, the first vertical part and the slot sidewall are located on the same vertical plane, which can further provide a stable support structure for the upper slot part. When the frame is subjected to positive, negative and torsional loads, it can maintain stable support, ensure that the two layers of materials do not separate, and the overall structure is not easy to become unstable.

[0035] Furthermore, in the steel closed frame of the present invention, the connecting arm extends horizontally from the lower end of the closed portion, the connecting arm has at least two layers of steel, and the outer end of the connecting arm has a transition rounded corner.

[0036] In this invention, the transition fillet can avoid surface cracks caused when the material is bent at 180°, increase the material adaptability window, and at the same time ensure that the upper and lower layers of material are in close contact.

[0037] Furthermore, in the steel closed frame described in this invention, the inner radius of the transition fillet R2 = k4 × t, where t represents the single-layer thickness of the steel, and the value range of the fourth adjustment coefficient k4 is 0.2 to 1.

[0038] Compared with the prior art, the steel closed-frame of the present invention has the following advantages:

[0039] The closed photovoltaic steel frame of the present invention can form a stable positive load-bearing capacity and torsional resistance through mutual support and covering of its own structure, avoiding insufficient load-bearing capacity caused by separation and displacement of the two layers of materials during load-bearing. Moreover, it has a certain elastic space to reduce the risk of glass panel breakage during load-bearing. At the same time, the frame is roll-formed and is not prone to surface cracking. Attached Figure Description

[0040] Figure 1 A cross-sectional view of the steel closed frame according to one embodiment of the present invention is shown.

[0041] Figure 2 A cross-sectional view of the steel closed frame described in one embodiment of the present invention is further shown.

[0042] Figure 3 A cross-sectional view of the steel closed frame described in one embodiment of the present invention is further shown. Detailed Implementation

[0043] The steel closed frame of the present invention will be further explained and described below with reference to the accompanying drawings and specific embodiments. However, this explanation and description do not constitute an undue limitation on the technical solution of the present invention.

[0044] Figure 1 A cross-sectional view of the steel closed frame according to one embodiment of the present invention is shown.

[0045] like Figure 1 As shown, in this embodiment, the steel closed frame is an integral structure made of steel through multiple roll forming processes.

[0046] In some more specific embodiments, the thickness t of a single layer of steel can be 0.4 to 0.8 mm.

[0047] Continue reading Figure 1 The steel closed-type frame generally includes: a slot portion 1 with an open end, a closed portion 2 located below the slot portion 1, and a connecting arm 3 extending from the lower end of the closed portion 2, the extension direction of the connecting arm 3 being consistent with the orientation of the open end of the slot portion 1. The slot portion 1 is fitted with a battery glass assembly G; the closed portion 2 is a closed cavity structure and is the main load-bearing structure supporting the battery glass assembly; the connecting arm 3 is mainly used for connection with the photovoltaic support (not shown in the figure).

[0048] Figure 2 A cross-sectional view of the steel closed frame described in one embodiment of the present invention is further shown.

[0049] Figure 3A cross-sectional view of the steel closed frame described in one embodiment of the present invention is further shown.

[0050] like Figure 2 As shown, in some more specific embodiments, the slot portion 1 may include a top 11, a slot sidewall 12, and a bottom 13 shared with the closing portion 2.

[0051] like Figure 3 As shown, in some more specific embodiments, the top 11 slopes downward in the direction extending outward from the slot sidewall 12 to form an angle α1 with the bottom 13. In some more specific embodiments, the angle α1 ranges from 4 to 10°.

[0052] Continue reading Figure 2 In some specific embodiments, the outer edge 14 of the top 11 of the slot portion 1 has three layers of steel. Furthermore, the outer edge 14 of the top 11 of the slot portion 1 has a closed edge structure, and the cross-section of the steel faces the sidewall 12 of the slot.

[0053] In some specific embodiments, a first rounded corner portion 15 is provided between the top 11 of the slot portion 1 and the side wall 12 of the slot portion 1. The first rounded corner portion 15 has two layers of steel to form a first upper rounded corner portion 151 and a first lower rounded corner portion 152, wherein the inner rounded corner radius of the first upper rounded corner portion 151 is smaller than the outer rounded corner radius of the first lower rounded corner portion 152.

[0054] In some specific embodiments, the radius difference ΔR1 between the inner radius of the first upper rounded corner 151 and the outer radius of the first lower rounded corner 152 during the roll forming process can be 0.2 × t, where t represents the single-layer thickness of the steel. In this way, during the roll forming process, the inner rounded corner of the lower layer is slightly smaller than the outer rounded corner of the upper layer, thus allowing the lower layer to have a certain degree of curvature for a tighter covering.

[0055] In some more specific embodiments, the outer radius of the first lower rounded corner 152 is R1 = k1 × t, and the value of the first adjustment coefficient k1 can be in the range of 1 to 2.

[0056] Continue reading Figure 2 In some specific embodiments, a second rounded corner portion 16 is provided between the bottom 13 of the slot portion 1 and the side wall 12 of the slot portion 1. The second rounded corner portion 16 has two layers of steel to form a second upper rounded corner portion 161 and a second lower rounded corner portion 162, wherein the inner rounded corner radius of the second lower rounded corner portion 162 is smaller than the outer rounded corner radius of the second upper rounded corner portion 161.

[0057] Similarly, in some more specific embodiments, the radius difference between the inner radius of the second lower rounded corner 162 and the outer radius of the second upper rounded corner 161 during the roll forming process can be ΔR2 = 0.2 × t, where t represents the single-layer thickness of the steel.

[0058] In some specific embodiments, the second lower rounded corner 162 has a horizontal segment 163 extending toward the opening end.

[0059] In some more specific embodiments, the extension length W of the horizontal segment 163 is W = k2 × t, where t represents the single-layer thickness of the steel, and the value of the second adjustment coefficient k2 can be in the range of 3 to 5.

[0060] like Figure 2 As shown, in some embodiments, the closing portion 2 includes an upper end 24, a first side wall 21, a second side wall 22, and a lower end 23 shared with the bottom 13 of the slot portion 1. The first side wall 21 includes a first inclined portion 211 and a first vertical portion 212 located below the first inclined portion 211. The second side wall 22 includes a second inclined portion 221 and a second vertical portion 222 located below the second inclined portion 221. Both the first inclined portion 211 and the second inclined portion 221 are inclined outward from top to bottom.

[0061] like Figure 3 As shown, in some more specific embodiments, the included angle α2 between the first inclined portion 211 and the lower end 23 can be 80 to 85°, the included angle α3 between the second inclined portion 221 and the lower end 23 is α2 + β, and the value range of the adjustment angle β can be 0 to 2°.

[0062] like Figure 3 As shown, in some more specific embodiments, the height H0 of the first vertical portion 212 and the second vertical portion 222 may be the same.

[0063] In a more specific implementation, H0 = k3 × H1, where H1 represents the total height of the closed portion, and the value of the third adjustment coefficient k3 ranges from 0.1 to 0.2.

[0064] In some preferred embodiments, the first vertical portion 212 and the slot sidewall 12 are located on the same vertical plane.

[0065] like Figure 2 and Figure 3 As shown, in some embodiments, the connecting arm 3 extends horizontally from the lower end of the closed portion 2, the connecting arm 3 has two layers of steel, and the outer end of the connecting arm 3 has a transition fillet 31.

[0066] like Figure 3As shown, in some more specific embodiments, the inner radius of the transition fillet 31 is R2 = k4 × t, where t represents the single-layer thickness of the steel, and the value of the fourth adjustment coefficient k4 can be in the range of 0.2 to 1.

[0067] To better illustrate the application of the steel closed-frame described in this invention, a specific example of the steel closed-frame is provided:

[0068] In this example, the steel closed frame is roll-formed from aluminum-zinc-aluminum-magnesium coated steel with a yield strength of 520 MPa and a thickness of t = 0.6 mm, forming the structure described above. Specifically, α1 is 5°, α2 is 84°, α3 is 86°, β is 2°, ΔR1 = 0.12 mm, the outer radius of the first lower rounded corner is R1 = 0.9 mm, the extension length of the horizontal section is W = 2 mm, the first adjustment coefficient k1 is 1.5, the second adjustment coefficient k2 is 3.33, the third adjustment coefficient k3 is 0.13, the fourth adjustment coefficient k4 is 0.67, the height H0 of the first and second vertical sections is 3 mm, the total height of the closed section is H1 = 23 mm, and the inner radius R2 of the transition rounded corner is 0.4 mm.

[0069] The closed-type steel frame obtained in this way does not experience surface cracking during roll forming and bending, has good corrosion resistance, and also has stable positive load and torsional bearing capacity.

[0070] It should be noted that the combination of the technical features in this case is not limited to the combination methods described in the claims of this case or the combination methods described in the specific embodiments. All technical features described in this case can be freely combined or combined in any way, unless they contradict each other.

[0071] It should also be noted that the embodiments listed above are merely specific embodiments of the present invention. Obviously, the present invention is not limited to the above embodiments, and similar changes or modifications made thereto are those that can be directly derived or easily conceived by those skilled in the art from the content disclosed in the present invention, and should all fall within the protection scope of the present invention.

Claims

1. A steel closed-frame, characterized in that, It is an integral structure made of steel through multiple roll forming processes. The steel closed frame includes: a slot with an open end, a closed part located below the slot, and a connecting arm extending from the lower end of the closed part. The extension direction of the connecting arm is consistent with the orientation of the open end of the slot.

2. The steel closed-frame as described in claim 1, characterized in that, The slot portion includes a top, a slot sidewall, and a bottom shared with the closure portion. The top is inclined downward in a direction extending outward from the slot sidewall to form an angle α1 with the bottom.

3. The steel closed-frame as described in claim 2, characterized in that, The included angle α1 ranges from 4 to 10°.

4. The steel closed-frame as described in claim 2, characterized in that, The outer edge of the top of the slot has at least three layers of steel.

5. The steel closed-frame as described in claim 2, characterized in that, The outer edge of the top of the slot has a closed edge structure, and the cross-section of the steel faces the side wall of the slot.

6. The steel closed-frame as described in claim 1, characterized in that, The top of the slot and the sidewall of the slot have a first rounded corner, the first rounded corner having at least two layers of steel to form a first upper rounded corner and a first lower rounded corner, wherein the inner rounded corner radius of the first upper rounded corner is smaller than the outer rounded corner radius of the first lower rounded corner.

7. The steel closed-frame as described in claim 6, characterized in that, The outer radius of the first lower rounded corner is R1 = k1 × t, where t represents the single-layer thickness of the steel, and the value range of the first adjustment coefficient k1 is 1 to 2.

8. The steel closed-frame as described in claim 1, characterized in that, The bottom of the slot and the sidewall of the slot have a second rounded corner portion, the second rounded corner portion having at least two layers of steel to form a second upper rounded corner portion and a second lower rounded corner portion, wherein the inner rounded corner radius of the second lower rounded corner portion is smaller than the outer rounded corner radius of the second upper rounded corner portion.

9. The steel closed-frame as described in claim 8, characterized in that, The second lower rounded corner has a horizontal section extending toward the opening end.

10. The steel closed-frame as described in claim 9, characterized in that, The extension length of the horizontal section is W = k2 × t, where t represents the single-layer thickness of the steel, and the value of the second adjustment coefficient k2 ranges from 3 to 5.

11. The steel closed-frame according to any one of claims 1-10, characterized in that, The closed portion includes an upper end, a first sidewall, a second sidewall, and a lower end shared with the bottom of the slot portion. The first sidewall includes a first inclined portion, and the second sidewall includes a second inclined portion. Both the first inclined portion and the second inclined portion are inclined outward from top to bottom.

12. The steel closed-frame as described in claim 11, characterized in that, The included angle α2 between the first inclined portion and the lower end is 80 to 85°.

13. The steel closed-frame as described in claim 11, characterized in that, The angle α3 between the second inclined part and the lower end is α2 + β, and the value of the adjustment angle β is in the range of 0 to 2°. α2 is the angle between the first inclined part and the lower end.

14. The steel closed-frame as described in claim 11, characterized in that, The first sidewall also includes a first vertical portion located below the first inclined portion, and the second sidewall also includes a second vertical portion located below the second inclined portion.

15. The steel closed-frame as described in claim 11, characterized in that, The first vertical part and the second vertical part have the same height.

16. The steel closed-frame as described in claim 14, characterized in that, The height H0 of the first vertical part and / or the second vertical part is k3 × H1, where H1 represents the total height of the closed part, and the value of the third adjustment coefficient k3 ranges from 0.1 to 0.

2.

17. The steel closed-frame as described in claim 14, characterized in that, The first vertical part and the side wall of the slot are located on the same vertical plane.

18. The steel closed-frame according to any one of claims 1-10, characterized in that, The connecting arm extends horizontally from the lower end of the closed portion, the connecting arm has at least two layers of steel, and the outer end of the connecting arm has a transition rounded corner.

19. The steel closed-frame as described in claim 18, characterized in that, The inner radius of the transition fillet is R2 = k4 × t, where t represents the single-layer thickness of the steel, and the value of the fourth adjustment coefficient k4 ranges from 0.2 to 1.

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