An integrated photovoltaic insulation board and a processing method thereof

Abstract

This invention discloses an integrated photovoltaic insulation board and its processing method, belonging to the field of building photovoltaic insulation board technology. It includes a flexible photovoltaic module, a core material, and a profiled steel sheet. The core material is disposed between the flexible photovoltaic module and the profiled steel sheet. The two ends of the profiled steel sheet are bent and extended towards the flexible photovoltaic module, and both ends of the profiled steel sheet form support and bonding areas. The flexible photovoltaic module is attached to the support and bonding areas. In this invention, the profiled steel sheet is die-cast. Compared to the traditional double-layer color steel sheet structure, the extended structure of the profiled steel sheet replaces the upper color steel sheet. Simultaneously, the flexible photovoltaic module is used to bond and encapsulate the top of the profiled steel sheet. Therefore, the flexible photovoltaic module can serve as both the outer surface layer and the power generation layer, reducing material consumption and significantly lowering manufacturing costs.

Description

Technical Field

[0001] This invention belongs to the field of building photovoltaic insulation board technology, and particularly relates to an integrated molding photovoltaic insulation board and its processing method. Background Technology

[0002] A photovoltaic BIPV system that combines metal roofing and walls. Traditional photovoltaic BIPV systems are single-layer metal profiled panels or metal sandwich panels, and the modules are two independent products that are fixed by adhesive or clips at the back, requiring secondary assembly.

[0003] However, in actual use, existing wall-mounted BIPV is basically a photovoltaic curtain wall, which is a glass-based rigid photovoltaic module and the glass of the original glass curtain wall. It is heavy, has limited size and specifications, is complicated to process and expensive. In order to solve the above problems, there is an urgent need for an integrated photovoltaic insulation board and processing method. Summary of the Invention

[0004] The purpose of this invention is to solve the problem of the cumbersome processing of traditional photovoltaic curtain walls, and to propose an integrated photovoltaic insulation board and processing method.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: an integrated photovoltaic insulation board, comprising a flexible photovoltaic module, a core material and a profiled steel sheet, wherein the core material is disposed between the flexible photovoltaic module and the profiled steel sheet;

[0006] The two ends of the profiled steel sheet are bent and extended toward the flexible photovoltaic module, and support bonding areas are formed at both ends of the profiled steel sheet. The flexible photovoltaic module is attached to the support bonding area.

[0007] As a further description of the above technical solution:

[0008] Both sides of the top of the profiled steel sheet are provided with anti-capillary grooves, and high-pressure foaming adhesive is provided between the core material and the profiled steel sheet.

[0009] As a further description of the above technical solution:

[0010] Structural adhesive is provided between the flexible photovoltaic module and the support bonding area, and the structural adhesive is located on both sides of the anti-capillary groove.

[0011] As a further description of the above technical solution:

[0012] The core material is an inorganic thermal insulation material.

[0013] As a further description of the above technical solution:

[0014] One end of the profiled steel sheet is provided with a waterproof socket end, and the other end of the profiled steel sheet away from the waterproof socket end is provided with a corresponding waterproof insertion end.

[0015] As a further description of the above technical solution:

[0016] The profiled steel sheet is installed on one side of a junction box, and the junction box is connected to the flexible photovoltaic module through a power line.

[0017] As a further description of the above technical solution:

[0018] Both sides of the junction box are connected to DC lines, and the other end of the DC lines is connected to an external energy storage device.

[0019] As a further description of the above technical solution:

[0020] A flexible protective layer is provided between the flexible photovoltaic module and the core material, and the flexible protective layer is attached to one side of the flexible photovoltaic module and the other side of the core material.

[0021] As a further description of the above technical solution:

[0022] The profiled steel sheet may have a bending groove on the side away from the core material.

[0023] A method for processing an integrated photovoltaic insulation board includes the following steps:

[0024] S1: Cut the flexible photovoltaic modules as needed and arrange them into units according to power generation requirements;

[0025] S2: The profiled steel sheet is placed into the bending and die-casting machine for die casting, and then the core material is placed into the profiled steel sheet. The gap between the core material and the profiled steel sheet is then filled with high-pressure foam adhesive.

[0026] S3: The assembled flexible photovoltaic modules are bonded and installed with profiled steel sheets and fixed to form a photovoltaic insulation board.

[0027] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are:

[0028] 1. In this invention, profiled steel sheets are die-cast to form the upper color steel sheet, which is different from the traditional double-layer color steel sheet structure. The profiled steel sheet extension structure is used to replace the upper color steel sheet, and flexible photovoltaic modules are used to bond and encapsulate the top of the profiled steel sheet. Therefore, the flexible photovoltaic modules can serve as both the outer sheet surface layer and the power generation layer, reducing the consumption of sheet materials and significantly reducing manufacturing costs.

[0029] 2. In this invention, the flexible photovoltaic module and the profiled steel sheet are integrally formed, which allows the device to replace the traditional photovoltaic module that requires secondary adhesive bonding on site. This improves assembly efficiency and avoids the problems of difficult-to-control bonding quality and installation position deviation caused by manual construction on site, thereby improving the overall structural stability.

[0030] 3. In this invention, by setting structural adhesive, the flexible photovoltaic module and the profiled steel sheet are sealed to prevent rainwater intrusion. This prevents rainwater from entering the profiled steel sheet through the gap between the flexible photovoltaic module and the profiled steel sheet, thus avoiding the rainwater adhering to the core material. Therefore, it avoids the internal insulation core material from getting damp, increasing its thermal conductivity, and aging prematurely. Attached Figure Description

[0031] Figure 1 This is a top-view schematic diagram of the structure proposed in this invention;

[0032] Figure 2 This is a schematic diagram of the side cross-sectional structure proposed in this invention;

[0033] Figure 3 This is a schematic diagram of the profiled steel sheet structure proposed in this invention;

[0034] Figure 4 This is a schematic diagram of the flexible photovoltaic module structure proposed in this invention;

[0035] Figure 5 This is a schematic diagram of the bending groove structure proposed in this invention.

[0036] Legend:

[0037] 1. Flexible photovoltaic module; 2. Corrugated steel sheet; 3. Junction box; 4. DC cable; 5. High-pressure foam; 6. Core material; 7. Waterproof socket end; 8. Waterproof plug end; 9. Anti-capillary groove; 10. Flexible protective layer; 11. Structural adhesive; 12. Bending groove. Detailed Implementation

[0038] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0039] Please see Figures 1-5 The present invention provides a technical solution: an integrated photovoltaic insulation board, comprising a flexible photovoltaic module 1, a core material 6 and a profiled steel sheet 2, wherein the core material 6 is disposed between the flexible photovoltaic module 1 and the profiled steel sheet 2;

[0040] The two ends of the profiled steel sheet 2 are bent and extended toward the flexible photovoltaic module 1, and both ends of the profiled steel sheet 2 form a support bonding area, on which the flexible photovoltaic module 1 is attached.

[0041] Furthermore, core material 6 is an inorganic thermal insulation material.

[0042] Furthermore, one end of the profiled steel sheet 2 is provided with a waterproof socket end 7, and the end of the profiled steel sheet 2 away from the waterproof socket end 7 is provided with a corresponding waterproof spigot end 8.

[0043] Furthermore, the profiled steel sheet 2 is installed on one side of the junction box 3, and the junction box 3 is connected to the flexible photovoltaic module 1 through a power line.

[0044] Furthermore, both sides of the junction box 3 are connected to DC lines 4, and the other end of the DC lines 4 is connected to an external energy storage device.

[0045] Furthermore, a flexible protective layer 10 is provided between the flexible photovoltaic module 1 and the core material 6, and the flexible protective layer 10 is attached to one side of the flexible photovoltaic module 1 and one side of the core material 6.

[0046] The specific implementation method is as follows: the profiled steel sheet 2 is die-cast and formed, and the extended structure of the profiled steel sheet 2 is used to replace the upper color steel sheet. At the same time, the flexible photovoltaic module 1 is used to bond and encapsulate the top of the profiled steel sheet 2. Therefore, the flexible photovoltaic module 1 can serve as both the outer panel and the power generation layer, reducing the consumption of sheet materials and significantly reducing manufacturing costs. Furthermore, by setting the flexible protective layer 10, damage to the flexible photovoltaic module 1 caused by glue and mechanical extrusion during the production process can be effectively avoided, thereby improving the product yield and service life.

[0047] A bending groove 12 may be provided on the side of the profiled steel sheet 2 away from the core material 6.

[0048] The specific implementation method is as follows: the flexible photovoltaic module 1 and the profiled steel sheet 2 are integrally formed, so that the device can replace the traditional photovoltaic module that requires secondary adhesive bonding on site. Therefore, the assembly efficiency can be improved. At the same time, it can also avoid the problems of poor bonding quality and installation position deviation caused by manual construction on site, which leads to low installation quality and thus improves the overall structural stability. Furthermore, by setting the bending groove 12 at the bottom of the profiled steel sheet 2, the profiled steel sheet 2 can be bent, so the device can be bent and fitted according to the roof, thereby improving the applicability of the device.

[0049] Both sides of the top of the profiled steel sheet 2 are provided with anti-capillary grooves 9, and high-pressure foaming adhesive 5 is provided between the core material 6 and the profiled steel sheet 2.

[0050] Furthermore, a structural adhesive 11 is provided between the flexible photovoltaic module 1 and the support bonding area, and the structural adhesive 11 is located on both sides of the anti-capillary groove 9.

[0051] The specific implementation method is as follows: By setting up structural adhesive 11, the flexible photovoltaic module 1 and the profiled steel sheet 2 are sealed with structural adhesive 11 to prevent rainwater intrusion. This prevents external rainwater from entering the profiled steel sheet 2 through the gap between the flexible photovoltaic module 1 and the profiled steel sheet 2, thus preventing rainwater from adhering to the core material 6. Therefore, it avoids the internal insulation core material 6 from getting damp, increasing its thermal conductivity, and aging prematurely. Furthermore, by setting up anti-capillary grooves 9, when the structural adhesive 11 has defects in local application or the adhesive fails unexpectedly, the anti-capillary grooves 9 can block the flow, forming a second effective waterproof structure, further improving the sealing effect.

[0052] Working principle: In use, the core material 6 is placed inside the profiled steel sheet 2, and then filled with high-pressure foam 5 to avoid gaps between the core material 6 and the profiled steel sheet 2 that would affect the insulation effect. Then, the flexible photovoltaic module 1 is installed on top of the profiled steel sheet 2, thus forming an integrated device. This allows the device to be installed as a whole as needed, avoiding the need for secondary on-site installation that could lead to installation deviations and affect safety. Furthermore, the flexible photovoltaic module 1 can be used as both a power generation device and an encapsulation device, thus reducing the consumption of sheet materials and lowering production costs.

[0053] In this invention, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance; the term "multiple" refers to two or more unless otherwise explicitly defined. The terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; "linking" can be a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0054] 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 (e.g., changes in the size, dimensions, structure, shape, and proportions of various elements, as well as parameter values ​​(e.g., temperature, pressure, etc.), mounting arrangements, use of materials, color, orientation, etc.) without substantially departing from the novel teachings and advantages of the subject matter described in this application). For example, 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.

[0055] Furthermore, in order to provide a concise description of exemplary embodiments, not all features of actual embodiments (i.e., those features that are not relevant to the best mode of carrying out the invention as currently considered, or those features that are not relevant to implementing the invention) may be omitted.

[0056] It should be understood that numerous specific implementation decisions can be made during the development of any actual implementation method, and in any engineering or design project. Such development efforts may be complex and time-consuming, but for those of ordinary skill 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.

[0057] 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. An integrally formed photovoltaic insulation panel, characterized by, It includes a flexible photovoltaic module (1), a core material (6) and a profiled steel sheet (2), wherein the core material (6) is disposed between the flexible photovoltaic module (1) and the profiled steel sheet (2); The two ends of the profiled steel sheet (2) are bent and extended toward the flexible photovoltaic module (1), and both ends of the profiled steel sheet (2) form a support bonding area, on which the flexible photovoltaic module (1) is attached.

2. The integrally formed photovoltaic insulation panel of claim 1, wherein, The top two sides of the profiled steel sheet (2) are provided with anti-capillary grooves (9), and high-pressure foaming adhesive (5) is provided between the core material (6) and the profiled steel sheet (2).

3. The integrally formed photovoltaic insulation panel of claim 1, wherein, Structural adhesive (11) is provided between the flexible photovoltaic module (1) and the support bonding area, and the structural adhesive (11) is located on both sides of the anti-capillary groove (9).

4. The integrally formed photovoltaic insulation panel of claim 1, wherein, The core material (6) is an inorganic thermal insulation material.

5. The integrally formed photovoltaic insulation panel of claim 1, wherein, The profiled steel sheet (2) has a waterproof socket end (7) at one end, and a corresponding waterproof insert end (8) at the other end of the profiled steel sheet (2) away from the waterproof socket end (7).

6. The integrally formed photovoltaic insulation panel of claim 1, wherein, The profiled steel sheet (2) is installed on one side of the junction box (3), and the junction box (3) is connected to the flexible photovoltaic module (1) through a power line.

7. The integrated molded photovoltaic insulation board according to claim 6, characterized in that, Both sides of the junction box (3) are connected to DC lines (4), and the other end of the DC lines (4) is connected to an external energy storage device.

8. The integrated molded photovoltaic insulation board according to claim 1, characterized in that, A flexible protective layer (10) is provided between the flexible photovoltaic module (1) and the core material (6), and the flexible protective layer (10) is attached to one side of the flexible photovoltaic module (1) and one side of the core material (6).

9. The integrated molded photovoltaic insulation board according to claim 1, characterized in that, The profiled steel sheet (2) may have a bending groove (12) on the side away from the core material (6).

10. A method for processing an integrated photovoltaic insulation board, characterized in that, The application of an integrated molded photovoltaic insulation board according to any one of claims 1-9 specifically includes the following steps: S1: Cut the flexible photovoltaic module (1) as needed and arrange the units according to the power generation requirements; S2: Place the profiled steel sheet (2) into the bending die casting machine for die casting, then place the core material (6) into the profiled steel sheet (2), and then fill the gap between the core material (6) and the profiled steel sheet (2) with high-pressure foaming adhesive (5); S3: The assembled flexible photovoltaic modules (1) are bonded and installed with the profiled steel sheet (2) and fixed to form a photovoltaic insulation board.

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