A method for preparing an aluminum frame of a solar photovoltaic panel

Abstract

This invention belongs to the technical field of aluminum frame manufacturing for solar photovoltaic panels. Specifically, it proposes a method for preparing aluminum frames for solar photovoltaic panels, comprising: melting Al-Si, Al-Zr, Al-Mn, Al-Cr, Al-Fe, Al-Ti, and Al-Zn master alloys, Al ingots, Cu ingots, and Mg ingots in a melting furnace to obtain an aluminum liquid mixture; performing slag removal and heating treatment to obtain an aluminum alloy liquid; placing the aluminum alloy liquid in a settling furnace and refining it using inert gas spraying; injecting the aluminum alloy liquid into a mold through a flow channel, and adding Al-Ti-B wire in the flow channel through a wire feeder, and casting using a hot-top method or an air-slip method to obtain an aluminum alloy block; performing homogenization treatment to obtain an aluminum alloy rod; performing heating, heat preservation, extrusion, and cooling treatment to obtain an aluminum alloy substrate; and performing stretching straightening, aging treatment, and oxidation treatment to obtain the aluminum frame. This invention improves the strength and hardness of the aluminum frame by controlling the element content in the aluminum alloy and the aluminum alloy raw material preparation process.

Description

Technical Field

[0001] This invention relates to the field of aluminum frame manufacturing technology for solar photovoltaic panels, and specifically to a method for preparing aluminum frames 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] Currently, solar photovoltaic panels are widely used in various industries, which inevitably requires them to be installed in harsh environments. This makes the aluminum frames of solar photovoltaic panels more susceptible to corrosion, shortening their service life and increasing operating costs. Therefore, it is particularly important to develop a method for preparing aluminum frames for solar photovoltaic panels to improve their strength and corrosion resistance. Summary of the Invention

[0005] To address the aforementioned problems, this invention provides a method for preparing an aluminum frame for a solar photovoltaic panel, 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 method for manufacturing an aluminum frame for a solar photovoltaic panel, the method comprising the following steps: Step S1: Place Al-Si, Al-Zr, Al-Mn, Al-Cr, Al-Fe, Al-Ti and Al-Zn master alloys, Al ingots, Cu ingots and Mg ingots in a melting furnace and melt them to obtain an aluminum liquid mixture; Step S2: Remove slag and heat the aluminum liquid mixture to obtain aluminum alloy liquid; Step S3: Place the molten aluminum alloy into a settling furnace and refine it by blowing inert gas. Step S4: The refined aluminum alloy liquid is injected into the mold through the flow channel, and Al-Ti-B wire is added into the flow channel through the wire feeder. The aluminum alloy block is obtained by casting using the hot top method or the air sliding method. Step S5: Homogenize the cast aluminum alloy block to obtain an aluminum alloy rod. Step S6: The aluminum alloy rod is heated, heat-held, extruded and cooled to obtain the aluminum alloy substrate; Step S7: After stretching, straightening, aging, and oxidizing the aluminum alloy substrate, an aluminum frame for the solar photovoltaic panel is obtained. Further, 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%.

[0007] Furthermore, in step S1, the temperature of the aluminum liquid mixture obtained after melting treatment is 700-760℃.

[0008] Furthermore, in step S2, before slag removal and heating of the aluminum molten mixture, a sample of the mixture is taken for analysis, and elements are added according to the analysis results, controlling the mass percentage of Mg to be 0.40–0.70%; Si to 0.60–0.90%; Fe to 0.05–0.25%; Zr to 0.05–0.15%; Zn to 0.05–0.1%; Ti to 0.05–0.10%; Cr to 0.03–0.08%; Cu to 0.03–0.10%; and Mn to 0.03–0.07%.

[0009] Furthermore, when sampling and analyzing the aluminum liquid mixture, the temperature is controlled to be no lower than 700℃; and the temperature of the aluminum alloy liquid obtained after heating is controlled to be 715-730℃.

[0010] Furthermore, in step S3, the specific method for spray refining is as follows: nitrogen is used for spray refining, and the refining time is controlled to be 0.5-1 hour, and the temperature of the aluminum alloy liquid is 720-740℃.

[0011] Furthermore, in step S4, the speed at which the Al-Ti-B wire is fed into the wire feeder is 3-5 m / min; the casting speed during the casting process is 110-120 mm / min.

[0012] Furthermore, in step S5, the specific method for homogenizing the cast aluminum alloy block is as follows: Step S5-1: Increase the temperature to 470℃ at a rate of 20-100℃ / L and hold for 3 hours; Step S5-2: Increase the temperature to 570℃ at a rate of 150-250℃ / L and hold for 1-3 hours; Step S5-3: Cool to 200-300℃ with strong airflow, then allow to cool naturally to room temperature.

[0013] Furthermore, in step S6, the heating temperature is 440–510°C; the holding time is 3–4 hours; the extrusion process is forward extrusion, and the temperature is cooled to below 250°C at a rate of 1–3°C / s during the extrusion process.

[0014] Furthermore, in step S7, during the stretching and straightening operation, the stretching rate is 0.5-1.2%; the specific method for the aging treatment operation is as follows: first, heat to 175-195℃ at a rate of 80-120℃ / h, hold for 3-6 hours, and then cool to below 40℃ at a rate of 100-140℃ / h after being taken out of the furnace.

[0015] The beneficial effects of the technical solution described in this invention are as follows: 1. This invention controls the types and contents of elements in aluminum alloy raw materials, and refines the aluminum alloy liquid mixture by removing slag, heating and blowing, thereby giving the aluminum alloy raw materials excellent plasticity and making them easy to form. At the same time, it can refine the grains and improve the strength and hardness of the profile, thus meeting the requirements of large-size solar photovoltaic panels for frame materials.

[0016] 2. By homogenizing the cast aluminum alloy block and performing stretching, straightening, and aging treatments on the aluminum alloy substrate, the present invention enables the resulting aluminum alloy frame to have excellent elongation, thereby maintaining good plastic deformation capacity under external force, thus improving the overall stability of the photovoltaic panel and further enhancing the strength of the aluminum frame. Attached Figure Description

[0017] 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.

[0018] Figure 1 This is a flowchart of the method for preparing the aluminum frame of a solar photovoltaic panel according to the present invention. Detailed Implementation

[0019] 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.

[0020] like Figure 1 As shown, this invention proposes a method for manufacturing an aluminum frame for a solar photovoltaic panel, comprising the following steps: Step S1: Place Al-Si, Al-Zr, Al-Mn, Al-Cr, Al-Fe, Al-Ti and Al-Zn master alloys, Al ingots, Cu ingots and Mg ingots in a melting furnace for melting treatment, and control the temperature of the resulting aluminum liquid mixture to 720℃.

[0021] Preferably, during the melting process, the temperature of the aluminum molten mixture is controlled to be no lower than 700℃. Simultaneously, the aluminum molten mixture is sampled and analyzed in real time to determine the percentage content of each element. Based on the analysis results, the corresponding elements are supplemented. The content of each component in the aluminum molten mixture is controlled as follows: Mg 0.5% by mass; Si 0.8% by mass; Fe 0.15% by mass; Zr 0.09% by mass; Zn 0.08% by mass; Ti 0.07% by mass; Cr 0.05% by mass; Cu 0.06% by mass; Mn 0.05% by mass, with the remainder being aluminum.

[0022] Step S2: Remove slag from the aluminum liquid mixture and heat it up, controlling the temperature of the resulting aluminum alloy liquid to be 720℃.

[0023] Step S3: Place the molten aluminum alloy into a settling furnace, control the temperature of the molten aluminum alloy to 730℃, introduce nitrogen into the settling furnace for spray refining, and control the refining time to 0.6 hours.

[0024] Step S4: The refined aluminum alloy liquid is injected into the mold through the flow channel, and Al-Ti-B wire is added into the flow channel at a speed of 4m / min by the wire feeder. Casting is carried out by hot top method or air sliding method, and the casting speed is controlled at 110mm / min to obtain aluminum alloy block.

[0025] Step S5: Homogenize the cast aluminum alloy block to obtain an aluminum alloy rod.

[0026] Specifically, the homogenization process is as follows: first, heat the material to 470℃ at 50℃ / L and hold it for 3 hours; then heat it to 570℃ at 200℃ / L and hold it for 2 hours; then cool it down to 200℃ using strong air; and finally, allow it to cool naturally to room temperature.

[0027] Step S6: Heat the aluminum alloy rod to 480℃ and hold it at that temperature for 3 hours. Then, feed the aluminum alloy rod into the extruder and extrude it using a forward extrusion method.

[0028] Preferably, during the extrusion process, the material is cooled to below 250°C at a rate of 2°C / s to obtain an aluminum alloy substrate.

[0029] Step S7: After stretching, straightening, aging and oxidizing the aluminum alloy substrate, an aluminum frame for solar photovoltaic panels is obtained.

[0030] Specifically, when performing stretching and straightening on the aluminum alloy substrate, the stretching rate is 0.8%; when performing aging treatment on the aluminum alloy substrate, the specific method is as follows: first, heat to 180℃ at a rate of 100℃ / h, hold for 5 hours, and then cool to below 40℃ at a rate of 120℃ / h after taking it out of the furnace.

[0031] This invention controls the types and content of elements in aluminum alloy raw materials, and refines the aluminum alloy liquid mixture through slag removal, heating, and spraying, thereby giving the aluminum alloy raw materials excellent plasticity and making them easy to form. At the same time, it can refine the grains and improve the strength and corrosion resistance of the profiles, thus meeting the requirements of large-size solar photovoltaic panels for frame materials.

[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 method for manufacturing an aluminum frame for a solar photovoltaic panel, characterized in that, The method includes the following steps: Step S1: Place Al-Si, Al-Zr, Al-Mn, Al-Cr, Al-Fe, Al-Ti and Al-Zn master alloys, Al ingots, Cu ingots and Mg ingots in a melting furnace and melt them to obtain an aluminum liquid mixture; Step S2: Remove slag and heat the aluminum liquid mixture to obtain aluminum alloy liquid; Step S3: Place the molten aluminum alloy into a settling furnace and refine it by blowing inert gas. Step S4: The refined aluminum alloy liquid is injected into the mold through the flow channel, and Al-Ti-B wire is added into the flow channel through the wire feeder. The aluminum alloy block is obtained by casting using the hot top method or the air sliding method. Step S5: Homogenize the cast aluminum alloy block to obtain an aluminum alloy rod. Step S6: The aluminum alloy rod is heated, heat-held, extruded and cooled to obtain the aluminum alloy substrate; Step S7: After stretching, straightening, aging and oxidizing the aluminum alloy substrate, an aluminum frame for solar photovoltaic panels is obtained.

2. The method for preparing an aluminum frame for a solar photovoltaic panel according to claim 1, characterized in that, In step S1, the temperature of the aluminum liquid mixture obtained after melting treatment is 700-760℃.

3. The method for preparing the aluminum frame of a solar photovoltaic panel according to claim 1, characterized in that, In step S2, before slag removal and heating of the aluminum molten mixture, a sample of the mixture is taken for analysis, and elements are added according to the analysis results. The mass percentages of Mg, Si, Fe, Zr, Zn, Ti, Cr, Cu, and Mn are controlled as follows: 0.40–0.70%; 0.60–0.90%; 0.05–0.25%; 0.05–0.15%; 0.05–0.1%; 0.05–0.10%; 0.03–0.08%; 0.03–0.10%; and 0.03–0.07%.

4. The method for preparing the aluminum frame of a solar photovoltaic panel according to claim 3, characterized in that, When sampling and analyzing the aluminum liquid mixture, the temperature should be controlled to be no lower than 700℃; and the temperature of the aluminum alloy liquid obtained after heating should be controlled to be 715-730℃.

5. The method for preparing an aluminum frame for a solar photovoltaic panel according to claim 1, characterized in that, In step S3, the specific method for spray refining is as follows: nitrogen is used for spray refining, and the refining time is controlled to be 0.5-1 hour, and the temperature of the aluminum alloy liquid is 720-740℃.

6. The method for preparing an aluminum frame for a solar photovoltaic panel according to claim 1, characterized in that, In step S4, the Al-Ti-B wire is fed into the wire feeder at a speed of 3-5 m / min; the casting speed during the casting process is 110-120 mm / min.

7. The method for preparing an aluminum frame for a solar photovoltaic panel according to claim 1, characterized in that, In step S5, the specific method for homogenizing the cast aluminum alloy block is as follows: Step S5-1: Increase the temperature to 470℃ at a rate of 20-100℃ / L and hold for 3 hours; Step S5-2: Increase the temperature to 570℃ at a rate of 150-250℃ / L and hold for 1-3 hours; Step S5-3: Cool to 200-300℃ with strong airflow, then allow to cool naturally to room temperature.

8. The method for preparing an aluminum frame for a solar photovoltaic panel according to claim 1, characterized in that, In step S6, the heating temperature is 440-510℃; the holding time is 3-4h; the extrusion process is forward extrusion, and during the extrusion process, it is cooled to below 250℃ at a rate of 1-3℃ / s.

9. The method for preparing an aluminum frame for a solar photovoltaic panel according to claim 1, characterized in that, In step S7, during the stretching and straightening operation, the stretching rate is 0.5-1.2%; the specific method for the aging treatment operation is as follows: first, heat to 175-195℃ at a rate of 80-120℃ / h, hold for 3-6 hours, and then cool to below 40℃ at a rate of 100-140℃ / h after being taken out of the furnace.

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