Production process of solar photovoltaic panel aluminum frame profile

Abstract

This invention belongs to the field of aluminum frame manufacturing technology for solar photovoltaic panels. Specifically, it proposes a manufacturing process for aluminum frame profiles for solar photovoltaic panels, including: selecting aluminum alloy as the raw material and pre-treating it; placing the raw material in an extruder, setting the extrusion temperature to 400-500℃ and the extrusion ratio to 20-30, and performing extrusion molding using an extrusion die; after the profile cools and hardens, opening an injection groove on the inner surface of the profile's connecting cavity to facilitate subsequent bonding and assembly with the photovoltaic panel; immersing the profile in an electrolyte for anodizing; placing the anodized profile in a sealing liquid for sealing; inspecting the sealed profile, and conveying profiles that meet the inspection standards to an assembly table for assembly with the photovoltaic panel. This invention improves the overall performance of the aluminum frame profile by simultaneously quenching and anodizing the profile during the extrusion molding process.

Description

Technical Field

[0001] This invention relates to the field of aluminum frame manufacturing technology for solar photovoltaic panels, and specifically to a manufacturing process for aluminum frame profiles for solar photovoltaic panels. Background Technology

[0002] Solar energy, as an emerging energy source, is favored by people for its pollution-free and low-cost characteristics and has a wide range of applications. Moreover, with the widespread use of solar energy, the solar photovoltaic industry is gradually becoming a new sunrise industry.

[0003] With the rapid development of the photovoltaic industry, the requirements for the quality and performance of photovoltaic modules are increasing. Solar photovoltaic modules typically consist of solar cell modules and frames. Solar cell modules are generally composed of tempered glass, EVA layers, solar cells, EVA layers, and backsheets, which are assembled into one unit using a laminator. Frames are mostly made of aluminum alloy, and the aluminum frame is made of several profiles that are fixedly connected. As an important component of photovoltaic modules, the aluminum frame plays a role in protecting the modules and providing structural support.

[0004] The existing manufacturing process for aluminum frames typically involves bending sheet metal aluminum, which results in issues such as insufficient surface hardness, susceptibility to scratches, and poor corrosion resistance. These factors significantly impact the lifespan of the entire photovoltaic module. Summary of the Invention

[0005] To address the aforementioned problems, this invention provides a manufacturing process for aluminum frame profiles for solar photovoltaic panels, aiming to resolve the issues present in the background art.

[0006] To achieve the above objectives, the present invention proposes the following technical solution: A manufacturing process for aluminum frame profiles for solar photovoltaic panels, comprising the following steps: Step S1: Select aluminum alloy as the profile raw material and pre-treat the aluminum alloy raw material; Step S2: Place the pretreated raw material into the extruder, set the extrusion temperature to 400-500℃ and the extrusion ratio to 20-30, and perform extrusion molding in conjunction with the extrusion die; Step S3: After the profile has cooled and hardened, an injection groove is made on the inner surface of the profile connection cavity to facilitate subsequent bonding and assembly with the photovoltaic panel. Step S4: Place the extruded profile into an electrolyte for anodizing treatment; Step S5: Place the anodized profile into a sealing solution for sealing treatment; Step S6: The profiles that have undergone sealing are transported to the assembly station for assembly with photovoltaic panels, and the assembled photovoltaic modules are tested.

[0007] Furthermore, in step S1, the composition of the aluminum alloy raw material includes: aluminum, magnesium, silicon and copper; wherein the aluminum content is not less than 95%, the magnesium content is 1-3%, the silicon content is 0.5-1.5%, and the copper content is 0.1-0.5%.

[0008] Furthermore, in step S1, the specific method for pretreating the aluminum alloy raw material is as follows: the aluminum alloy raw material is cleaned with an alkaline solution, and the cleaning temperature is controlled at 40-60℃, and the cleaning time is 5-10 minutes.

[0009] Furthermore, in step S2, during the extrusion molding process, the profile is simultaneously quenched. During quenching, a combination of air cooling and water cooling is used for cooling, with a cooling rate of 100-200℃ / second; wherein the air speed is 5-10m / s; and the water temperature is 20-30℃.

[0010] Furthermore, in step S4, the electrolyte is a sulfuric acid solution with a concentration of 15-20%, the anodic oxidation voltage is 15-20V, the oxidation time is set to 30-60 minutes, and the oxidation temperature is 20-30℃.

[0011] Furthermore, in step S5, the sealing solution is a nickel salt solution, and the concentration of the nickel salt solution is controlled at 0.5-1 g / L, the sealing temperature is 90-100℃, and the sealing time is 15-30 minutes.

[0012] Furthermore, in step S6, the types of tests performed on the photovoltaic modules include: dimensional accuracy testing, surface hardness testing, and corrosion resistance testing.

[0013] The beneficial effects of the technical solution described in this invention are as follows: 1. This invention enhances the mobility of aluminum alloy atoms by controlling the extrusion temperature during extrusion molding, making the internal structure of the aluminum alloy relatively loose. This results in the aluminum alloy raw material having excellent plasticity and being easy to form. At the same time, by controlling the extrusion ratio, the microstructure of the aluminum alloy raw material can be improved and the grains refined, thereby increasing the strength and hardness of the profile.

[0014] 2. This invention improves the profile strength by simultaneously quenching the profile during the extrusion molding process, using a combination of water cooling and air cooling, and controlling the cooling rate, so that the supersaturated solid solution formed by the aluminum alloy at high temperature can be retained. Attached Figure Description

[0015] To make the content of this invention easier to understand, the invention will be further described in detail below with reference to specific embodiments and accompanying drawings.

[0016] Figure 1 This is a production process flow diagram of the aluminum frame profile for solar photovoltaic panels described in this invention. Detailed Implementation

[0017] The technical solution of the present invention will be further described below with reference to the accompanying drawings, but it is not limited thereto. Any modifications or equivalent substitutions to the technical solution of the present invention that do not depart from the spirit and scope of the technical solution of the present invention should be covered within the protection scope of the present invention.

[0018] like Figure 1 As shown, this invention proposes a manufacturing process for aluminum frame profiles of solar photovoltaic panels, which includes the following steps: Step S1: Select aluminum alloy as the profile raw material and pre-treat the aluminum alloy raw material.

[0019] Specifically, when selecting aluminum alloy raw materials, specific types of aluminum alloy materials are chosen, such as 6063-T5 aluminum alloy. The content of each element in the aluminum alloy raw materials is strictly controlled. The aluminum content is controlled at 96% to ensure that the aluminum frame has good electrical conductivity, thermal conductivity and machinability; the magnesium content is controlled at 2% to improve the casting performance and corrosion resistance of the aluminum frame; the silicon content is controlled at 1% to improve the casting performance and mechanical properties of the aluminum frame; and the copper content is controlled at 0.3% to improve the strength of the aluminum frame.

[0020] When pretreating aluminum alloy raw materials, sodium hydroxide solution is selected as an alkaline cleaning agent. An 8% sodium hydroxide solution is used to clean the aluminum alloy raw materials at a temperature of 50°C, and the cleaning time is controlled to be 8 minutes, so as to effectively remove impurities and oil stains from the aluminum alloy raw materials and ensure that the surface of the aluminum alloy raw materials is not excessively corroded.

[0021] Step S2: Place the pre-treated raw material into an extruder, set the extrusion temperature to 400-500℃ and the extrusion ratio to 20-30, and perform extrusion molding in conjunction with the extrusion die.

[0022] Specifically, the extrusion molding process is carried out using an extruder. During the extrusion process, the extrusion temperature is set to 450℃ and the extrusion ratio is set to 25. The extrusion is carried out according to the designed extrusion die. By controlling the extrusion temperature and extrusion ratio, the plasticity of the aluminum alloy can be improved, making it easier to form. At the same time, it can ensure that the aluminum frame profile has good microstructure and improve its strength.

[0023] Preferably, during the extrusion molding process, the profile is simultaneously quenched. During quenching, a combination of air cooling and water cooling is used. The quenching cooling rate is controlled at 150°C / second, and the air cooling rate is controlled at 8m / s to quickly remove the heat from the surface of the aluminum profile and initially reduce the temperature. The water cooling temperature is controlled at 25°C to further cool the aluminum frame profile quickly, so that the supersaturated solid solution formed at high temperature can be retained, thereby improving the strength.

[0024] Step S3: After the profile has cooled and hardened, an injection groove is made on the inner surface of the profile connection cavity to facilitate subsequent bonding and assembly with the photovoltaic panel.

[0025] Preferably, the glue injection grooves can be arranged at equal intervals or in a continuous long groove structure.

[0026] Step S4: Immerse the profile in the electrolyte for anodizing treatment; Specifically, the electrolyte is an 18% sulfuric acid solution to ensure the formation of a uniform and dense oxide film on the aluminum frame surface. The anodizing voltage is controlled at 18V, the oxidation time at 45 minutes, and the oxidation temperature at 25℃ to ensure uniform oxide film thickness and quality.

[0027] Step S5: Place the anodized profile into a sealing solution for sealing treatment.

[0028] Specifically, the sealing solution uses a nickel salt solution, and the concentration of the nickel salt solution is controlled at 0.6 g / L to further improve the density and corrosion resistance of the oxide film; the sealing temperature is controlled at 92℃ and the sealing time is controlled at 18 minutes to ensure that the sealing reaction is fully carried out, fill the pores in the oxide film, and improve the protective performance of the oxide film.

[0029] Step S6: Inspect the profiles after the sealing process, and transport the profiles that meet the inspection standards to the assembly table for assembly with photovoltaic panels.

[0030] Specifically, the testing of the profiles after sealing includes dimensional accuracy testing, surface hardness testing, and corrosion resistance testing. Dimensional testing ensures that the length, width, and thickness of the aluminum frame meet design requirements, thus guaranteeing the assembly accuracy of the photovoltaic modules. Surface hardness testing ensures that the aluminum frame reaches a Vickers hardness (HV) of 80-120, guaranteeing its resistance to external impacts and friction during use and preventing surface scratches and deformation. Corrosion resistance testing involves a salt spray test in a 5% sodium chloride (NaCl) solution for 72-168 hours, observing for any obvious corrosion on the aluminum frame surface. If the aluminum frame shows no significant corrosion within the specified time, it indicates good corrosion resistance, ensuring long-term use under various environmental conditions.

[0031] Specifically, during the assembly of the aluminum frame profiles and photovoltaic panels, silicone sealant is first injected into the injection groove. Then, the photovoltaic panels are bonded to the aluminum frame profiles on each side, and the various aluminum frame profiles are welded together to form a complete photovoltaic module. Using silicone sealant in the assembly process provides excellent weather resistance, allowing it to adapt to different environmental temperatures and humidity conditions. Simultaneously, it provides excellent sealing properties, preventing moisture and dust from entering the photovoltaic module and ensuring its normal operation.

[0032] It is important to note that the constructions and arrangements of this application shown in several different exemplary embodiments are merely illustrative. Although only a few embodiments are described in detail in this disclosure, those who consult this disclosure will readily understand that many modifications are possible without substantially departing from the novel teachings and advantages of the subject matter described in this application. For example, variations in the size, dimensions, structure, shape, and proportions of various elements, as well as parameter values ​​such as temperature, pressure, etc., installation arrangements, use of materials, color, orientation, etc. For instance, an element shown as integrally formed may be composed of multiple parts or elements, the position of elements may be inverted or otherwise altered, and the nature or number or position of discrete elements may be changed or altered. Therefore, all such modifications are intended to be included within the scope of the invention. The order or sequence of any process or method steps may be changed or rearranged according to alternative embodiments. In the claims, any "device plus function" clause is intended to cover the structure described herein that performs the function, and not only structurally equivalent but also equivalent in structure. Other substitutions, modifications, alterations, and omissions may be made in the design, operation, and arrangement of the exemplary embodiments without departing from the scope of the invention. Therefore, the present invention is not limited to the specific embodiments, but extends to various modifications that still fall within the scope of the appended claims.

[0033] Furthermore, in order to provide a concise description of exemplary embodiments, not all features of actual embodiments may be omitted, i.e., those features that are not relevant to the currently considered best mode for carrying out the invention, or those features that are not relevant to implementing the invention.

[0034] It should be understood that numerous specific implementation decisions can be made during the development of any practical implementation, such as in any engineering or design project. Such development efforts may be complex and time-consuming, but for those skilled in the art who benefit from this disclosure, the development effort will be a routine work of design, manufacturing, and production without requiring much experimentation.

[0035] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A manufacturing process for aluminum frame profiles for solar photovoltaic panels, characterized in that, The process includes the following steps: Step S1: Select aluminum alloy as the profile raw material and pre-treat the aluminum alloy raw material; Step S2: Place the pretreated raw material into the extruder, set the extrusion temperature to 400-500℃ and the extrusion ratio to 20-30, and perform extrusion molding in conjunction with the extrusion die; Step S3: After the profile has cooled and hardened, an injection groove is made on the inner surface of the profile connection cavity to facilitate subsequent bonding and assembly with the photovoltaic panel. Step S4: Immerse the profile in the electrolyte for anodizing treatment; Step S5: Place the anodized profile into a sealing solution for sealing treatment; Step S6: Inspect the profiles after the sealing process, and transport the profiles that meet the inspection standards to the assembly table for assembly with photovoltaic panels.

2. The manufacturing process of the aluminum frame profile for solar photovoltaic panels according to claim 1, characterized in that, In step S1, the aluminum alloy raw material comprises aluminum, magnesium, silicon and copper; wherein the aluminum content is not less than 95%, the magnesium content is 1-3%, the silicon content is 0.5-1.5%, and the copper content is 0.1-0.5%.

3. The manufacturing process of the aluminum frame profile for solar photovoltaic panels according to claim 1, characterized in that, In step S1, the specific method for pretreating the aluminum alloy raw material is as follows: use an alkaline solution to clean the aluminum alloy raw material, and control the cleaning temperature at 40-60℃ and the cleaning time at 5-10 minutes.

4. The manufacturing process of the aluminum frame profile for solar photovoltaic panels according to claim 1, characterized in that, In step S2, during the extrusion molding process, the profile is simultaneously quenched. During quenching, a combination of air cooling and water cooling is used for cooling, with a cooling rate of 100-200℃ / second; the air speed is 5-10m / s; and the water temperature is 20-30℃.

5. The manufacturing process of the aluminum frame profile for solar photovoltaic panels according to claim 1, characterized in that, In step S4, the electrolyte is a sulfuric acid solution with a concentration of 15-20%, the anodic oxidation voltage is 15-20V, the oxidation time is set to 30-60 minutes, and the oxidation temperature is 20-30℃.

6. The manufacturing process of the aluminum frame profile for solar photovoltaic panels according to claim 1, characterized in that, In step S5, the sealing solution is a nickel salt solution, and the concentration of the nickel salt solution is controlled at 0.5-1 g / L, the sealing temperature is 90-100℃, and the sealing time is 15-30 minutes.

7. The manufacturing process of the aluminum frame profile for solar photovoltaic panels according to claim 1, characterized in that, In step S6, the types of tests performed on the photovoltaic modules include: dimensional accuracy testing, surface hardness testing, and corrosion resistance testing.

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