A single-glass module with a multi-layer composite weather-resistant encapsulation structure

Abstract

This application discloses a single-glass module with a multi-layer composite weather-resistant encapsulation structure, relating to the field of photovoltaic equipment technology. It includes: a photovoltaic module comprising a photovoltaic laminate and a first frame, the photovoltaic laminate's edges covering the first frame, and a sealing silicone sealant filling the space between the photovoltaic laminate and the first frame; and a frame assembly comprising a second frame, a top plate, an elastic element, and a sealing strip. The second frame has a communicating first mounting cavity and a second mounting cavity. The first frame is inserted into the first mounting cavity, the top plate is movably disposed within the second mounting cavity, the elastic element is disposed between the top plate and the bottom surface of the second mounting cavity, and the top plate is tightly abutted against the first frame by the elastic force of the elastic element. The sealing strip is disposed at the opening of the first mounting cavity. After the photovoltaic module is inserted into the frame assembly, the sealing strip seals against the photovoltaic laminate. The beneficial effect of this application is that the disc spring, in conjunction with the top plate, achieves adaptive pressure adjustment, realizing dynamic compensation and avoiding the generation of micro-cracks.

Description

Technical Field

[0001] This application relates to the field of photovoltaic equipment technology, and in particular discloses a single-glass module with a multi-layer composite weather-resistant encapsulation structure. Background Technology

[0002] Single-glass modules are a basic structural form of photovoltaic modules. Their core feature is that they use only one layer of glass as the front panel, and encapsulate the cells with a back panel of multi-layer composite polymer materials (such as fluorine coating + PET substrate + adhesive layer). Compared with double-glass modules, which encapsulate the cells in the form of "front glass + back glass", single-glass modules achieve lightweight and low cost by using "front glass + polymer back panel".

[0003] However, traditional single-glass modules rely on silicone sealant to seal the gap between the frame and the photovoltaic laminate. The expansion coefficients of the photovoltaic laminate and the metal frame differ significantly. Under long-term temperature cycling, micro-gaps are easily generated at the interface, which traditional silicone sealant structures cannot compensate for. This leads to the sealant peeling off from the interface, allowing moisture to penetrate the interior and corrode the battery circuitry. At the same time, in the lamination process, the EVA film has insufficient adhesion strength to the glass and backsheet, which easily forms micro-cracks. In short, the sealing performance of existing single-glass modules needs to be improved. Utility Model Content

[0004] The purpose of this application is to provide a single-glass module with a multi-layer composite weather-resistant encapsulation structure.

[0005] To achieve the above objectives, the technical solution adopted in this application is as follows: a single-glass module with a multi-layer composite weather-resistant encapsulation structure, comprising: a photovoltaic module, the photovoltaic module including a photovoltaic laminate and a first frame, the photovoltaic laminate having its edge covered by the first frame, and a sealing silicone filling the space between the photovoltaic laminate and the first frame; a frame assembly, the frame assembly including a second frame, a top plate, an elastic element, and a sealing strip, the second frame having a communicating first mounting cavity and a second mounting cavity, the first frame being inserted into the first mounting cavity, the top plate being movably disposed within the second mounting cavity, the elastic element being disposed between the top plate and the bottom surface of the second mounting cavity, the top plate being tightly abutting against the first frame under the elastic force of the elastic element, and the sealing strip being disposed at the opening of the first mounting cavity, the sealing strip sealingly abutting against the photovoltaic laminate after the photovoltaic module is inserted into the frame assembly.

[0006] As a preferred embodiment, the second frame includes an integrally formed rectangular frame, a first vertical plate, a second vertical plate, and an upper horizontal plate. The first vertical plate is disposed on the upper left side of the rectangular frame, the upper horizontal plate is disposed on the upper end of the first vertical plate, and the second vertical plate is disposed on the upper right side of the rectangular frame. An opening for the first mounting cavity is formed between the right end of the upper horizontal plate and the upper end of the second vertical plate. A first stop strip is integrally formed on the right side of the first vertical plate, and a second stop strip is integrally formed on the left side of the second vertical plate. The first mounting cavity is formed between the first stop strip, the second stop strip, and the upper horizontal plate, and the second mounting cavity is formed between the first stop strip, the second stop strip, and the rectangular frame.

[0007] Further preferably, the bottom surface of the second mounting cavity is provided with a plurality of second mounting grooves, the elastic element is a disc spring, the disc spring is embedded in the second mounting groove, the lower side of the top plate abuts against the disc spring, in the natural state, the disc spring is in a preliminary compressed state, the top plate moves upward under the elastic force of the disc spring until its two sides abut against the lower sides of the first stop bar and the second stop bar respectively, the upper part of the top plate extends into the first mounting cavity, when the first frame is inserted into the first mounting cavity, the first frame squeezes the top plate to move it downward, further compressing the disc spring, under the elastic force of the disc spring, the top plate tightly abuts against the first frame.

[0008] In a further preferred embodiment, the lower side of the upper horizontal plate is provided with a positioning protrusion, and the first frame is provided with a corresponding positioning groove. After the first frame is inserted into the first mounting cavity, the positioning protrusion and the positioning groove are connected in cooperation.

[0009] In a further preferred embodiment, a protective part is provided at the right end of the upper horizontal plate, and a first mounting groove is provided on the side of the protective part facing the photovoltaic laminate. A first mounting groove is also provided at the upper end of the second vertical plate. A sealing strip is fixedly provided in the first mounting groove. After the photovoltaic module is inserted into the frame assembly, the sealing strip abuts tightly against the photovoltaic laminate.

[0010] Further preferably, the outer surface of the protective part is a sloped surface or an inclined curved surface. After the photovoltaic module is inserted into the frame assembly, the outer surface of the protective part transitions and joins with the surface of the photovoltaic laminate to form a flow guiding surface.

[0011] In a further preferred embodiment, the sealing strip has several sealing protrusions arranged in parallel to form a multi-level seal, and there are narrow slits between the sealing protrusions. If water vapor accidentally passes through the sealing protrusions, it will be trapped in the narrow slits under capillary action.

[0012] As a preferred embodiment, the rectangular frame is provided with a plurality of reinforcing ribs, which are distributed on the upper and lower sides of the rectangular frame and are arranged parallel to the length of the rectangular frame.

[0013] As a preferred embodiment, a plurality of material reduction grooves are arranged parallel to each other along the length of the second frame.

[0014] As a preferred embodiment, the first frame is provided with an overflow groove.

[0015] Compared with the prior art, the beneficial effects of this application are as follows:

[0016] (1) Adaptive pressure adjustment to achieve dynamic compensation: The disc spring and the top plate continuously provide adaptive clamping force during long-term temperature cycling. When the photovoltaic laminate and the first frame have slight relative displacement due to the difference in expansion coefficient, the top plate is adjusted in real time by the spring force of the disc spring to ensure that it is always tightly pressed against the first frame, eliminating the interface gap. This solves the problem that traditional sealing silicone cannot compensate for it, resulting in the separation of the sealing silicone from the interface, and avoids water vapor penetration. At the same time, the first frame receives the pressing pressure of the top plate at all times. This pressure is transmitted to the photovoltaic laminate, which can ensure that there is sufficient pressure between the EVA film and the glass and the back plate, avoiding the problem of easy formation of micro-cracks due to insufficient bonding strength, and strengthening the sealing performance.

[0017] (2) Secondary sealing to improve sealing performance: The sealing strip is directly pressed onto the surface of the photovoltaic laminate to form a wrapping secondary seal on the edge of the photovoltaic laminate. Even if the photovoltaic laminate and the first frame have minor cracks due to the difference in expansion coefficients or the edge of the photovoltaic laminate has micro-cracks due to insufficient bonding strength of the EVA film, the secondary sealing of the sealing strip can ensure that the whole device still has reliable sealing performance. Attached Figure Description

[0018] Figure 1 This is a three-dimensional structural diagram of the present invention.

[0019] Figure 2 This is an installation state diagram of this utility model.

[0020] Figure 3 This is a three-dimensional structural diagram of the frame component of this utility model.

[0021] Figure 4 This is an exploded view of the three-dimensional structure of the frame component of this utility model.

[0022] Figure 5 This is a three-dimensional structural diagram of the second frame of this utility model.

[0023] Figure 6 This is a schematic diagram of the second frame structure of this utility model.

[0024] Figure 7 This is a three-dimensional structural diagram of the laminate of this utility model.

[0025] In the diagram: 1. Second frame; 11. Upper horizontal plate; 111. Positioning protrusion; 112. Protective part; 12. First vertical plate; 121. First stop bar; 13. Second vertical plate; 131. Second stop bar; 14. First mounting groove; 15. First mounting cavity; 16. Second mounting cavity; 17. Second mounting groove; 18. Rectangular frame; 181. Reinforcing rib; 19. Material reduction groove; 2. Top plate; 3. Elastic element; 4. Sealing strip; 5. First frame; 51. Positioning groove; 52. Glue overflow groove; 6. Photovoltaic laminate; 7. Sealing silicone. Detailed Implementation

[0026] The present application will be further described below with reference to specific embodiments. It should be noted that, without conflict, the various embodiments or technical features described below can be arbitrarily combined to form new embodiments.

[0027] In the description of this application, it should be noted that the terms "center", "lateral", "longitudinal", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", etc., which indicate the orientation and positional relationship based on the orientation or positional relationship shown in the accompanying drawings, are only for the convenience of describing this application 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, and should not be construed as limiting the specific protection scope of this application.

[0028] It should be noted that the terms "first," "second," etc., in the specification and claims of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence.

[0029] The terms “comprising” and “having”, and any variations thereof, in the specification and claims of this application are intended to cover non-exclusive inclusion, for example, a process, method, system, product, or device that includes a series of steps or units is not necessarily limited to those steps or units that are explicitly listed, but may include other steps or units that are not explicitly listed or that are inherent to such process, method, product, or device.

[0030] A preferred embodiment of this application, such as Figures 1 to 7As shown, a single-glass module with a multi-layer composite weather-resistant encapsulation structure includes: a photovoltaic module, which includes a photovoltaic laminate 6 and a first frame 5, the photovoltaic laminate 6 having its edges covered by the first frame 5, and a sealing silicone 7 filling the space between the photovoltaic laminate 6 and the first frame 5; and a frame assembly, which includes a second frame 1, a top plate 2, an elastic element 3, and a sealing strip 4. The second frame 1 has a communicating first mounting cavity 15 and a second mounting cavity 16. The first frame 5 is inserted into the first mounting cavity 15, the top plate 2 is movably disposed in the second mounting cavity 16, the elastic element 3 is disposed between the top plate 2 and the bottom surface of the second mounting cavity 16, and the top plate 2 is tightly abutted against the first frame 5 by the elastic force of the elastic element 3. The sealing strip 4 is disposed at the opening of the first mounting cavity 15. After the photovoltaic module is inserted into the frame assembly, the sealing strip 4 seals against the photovoltaic laminate 6.

[0031] In this application, a double-frame combination structure is formed by setting a first frame 5 and a second frame 1. The first frame 5 serves as an inner skeleton, directly covering the edge of the photovoltaic laminate 6. The gap is filled by sealing silicone 7 to form a basic sealing layer. Similar to the prior art, it can ensure the structural integrity of the photovoltaic module and realize its basic functions. The second frame 1 serves as an outer functional frame. It solves the micro-crack problem that may exist in the prior art by integrating a dynamic sealing mechanism and a secondary sealing structure, and avoids the penetration of water vapor. The top plate 2, which serves as the dynamic sealing mechanism, cooperates with the disc spring to realize the dynamic pressure adjustment of the first frame 5, ensuring that the first frame 5 can be given sufficient abutment pressure under different conditions, and ensuring the seal between the first frame 5 and the photovoltaic laminate 6. The sealing strip 4, which serves as the secondary sealing structure, provides further sealing protection. Even if cracks appear between the photovoltaic laminate 6 and the first frame 5, the sealing strip 4 can still provide sufficient sealing performance.

[0032] To achieve dynamic sealing, this embodiment sets up a first mounting cavity 15 and a second mounting cavity 16 that are connected. The first mounting cavity 15 serves as the assembly cavity for the photovoltaic module, and the second mounting cavity 16 serves as the cavity for installing the dynamic sealing mechanism. A top plate 2 is set inside the second mounting cavity 16, and the top plate 2 can move within it in a restricted manner. The specific action can be simplified to floating up and down. The design of the dual-cavity structure makes the structural partitioning obvious and does not bring additional operational difficulties.

[0033] In addition, the double-frame design can greatly enhance the strength of the single-glass module.

[0034] Furthermore, such as Figures 5 to 6As shown, the second frame 1 includes an integrally formed rectangular frame 18, a first vertical plate 12, a second vertical plate 13, and an upper horizontal plate 11. The first vertical plate 12 is located on the upper left side of the rectangular frame 18, the upper horizontal plate 11 is located at the upper end of the first vertical plate 12, and the second vertical plate 13 is located on the upper right side of the rectangular frame 18. An opening of a first mounting cavity 15 is formed between the right end of the upper horizontal plate 11 and the upper end of the second vertical plate 13. A first baffle 121 is integrally formed on the right side of the first vertical plate 12, and a second baffle 131 is integrally formed on the left side of the second vertical plate 13. The first mounting cavity 15 is formed between the first baffle 121, the second baffle 131, and the upper horizontal plate 11, and a second mounting cavity 16 is formed between the first baffle 121, the second baffle 131, and the rectangular frame 18.

[0035] The aforementioned second frame 1 is integrally formed. The first vertical plate 12, the second vertical plate 13, the upper horizontal plate 11, and the upper frame of the rectangular frame 18 form a G-shaped cavity. The first mounting cavity 15 and the second mounting cavity 16 are separated by the first baffle 121 and the second baffle 131. The two are connected by the gap between the first baffle 121 and the second baffle 131, allowing the top plate 2 to float during this period. The above structural design is simple. At the same time, the first baffle 121 can serve as a reinforcing rib of the first vertical plate 12, improving its strength.

[0036] The second mounting cavity 16 serves as a cavity for installing the dynamic sealing mechanism. Specifically, it can be configured as follows: the bottom surface of the second mounting cavity 16 is provided with several second mounting grooves 17, which are circular grooves. The second mounting grooves 17 are evenly arranged along the length direction of the second frame 1. The elastic element 3 is a disc spring, which is embedded in the second mounting groove 17. The lower side of the top plate 2 abuts against the disc spring. With the structure of the first stop bar 121 and the second stop bar 131, the top plate 2 can be configured as a "convex" shaped structure. In its natural state, the disc spring is in a preliminary compressed state. The top plate 2 moves upward under the action of the disc spring until the stepped surfaces on both sides abut against the lower sides of the first stop bar 121 and the second stop bar 131, respectively. The upper part of the top plate 2 extends into the first mounting cavity 15. When the first frame 5 is inserted into the first mounting cavity 15, the first frame 5 squeezes the top plate 2 to move it downward, further compressing the disc spring. Under the action of the disc spring, the top plate 2 tightly abuts against the first frame 5.

[0037] It is clear that the disc spring is a non-linear elastic element. It is pre-compressed and installed in the second mounting groove 17 at the bottom of the second mounting cavity 16. The top plate 2 is floating on the upper side of the disc spring and is pushed upward against the first stop bar 121 and the second stop bar 131 by the elastic force of the disc spring. When the first frame 5 is inserted into the first mounting cavity 15, the top plate 2 will be pressed down and moved. At this time, the disc spring is compressed again. After installation, the top plate 2 continues to press the first frame 5 under the elastic force of the disc spring. During temperature cycling or when the photovoltaic module is displaced due to vibration, the top plate 2 can automatically adjust its position under the elastic force of the disc spring and still maintain the pressure against the first frame 5, thus achieving dynamic compensation. At the same time, since the photovoltaic module is not rigidly connected in the second frame 1, it is subjected to elastic contact, which can avoid stress concentration and edge cracking.

[0038] Furthermore, a positioning protrusion 111 is provided on the lower side of the upper horizontal plate 11, and a positioning groove 51 is provided on the first frame 5. After the first frame 5 is inserted into the first mounting cavity 15, the positioning protrusion 111 and the positioning groove 51 are connected. The above design facilitates the insertion of the photovoltaic module into the second frame 1. On the other hand, this limiting mechanism can prevent the photovoltaic module from lateral displacement with the second frame 1, ensuring its stable installation.

[0039] In detail, the upper horizontal plate 11 is further provided with a protective part 112 at the right end. The protective part 112 is provided with a first mounting groove 14 on the side facing the photovoltaic laminate 6. The upper end of the second vertical plate 13 is also provided with a first mounting groove 14. A sealing strip 4 is fixedly installed in the first mounting groove 14. After the photovoltaic module is inserted into the frame assembly, the sealing strip 4 is tightly abutted against the photovoltaic laminate 6. The outer surface of the protective part 112 is a slope or inclined curved surface. After the photovoltaic module is inserted into the frame assembly, the outer surface of the protective part 112 is transitionally joined with the surface of the photovoltaic laminate 6 to form a guide surface. Several sealing protrusions are arranged in parallel on the sealing strip 4 to form a multi-level seal. There are slits between the sealing protrusions. If water vapor accidentally passes through the sealing protrusions, it will be trapped in the slits under capillary action.

[0040] The aforementioned detailed design can also enhance sealing and extend product lifespan. Specifically, by setting the protective part 112, the outer surface of which is sloping or inclined curved, this guide surface design allows for a smooth transition with the surface of the photovoltaic laminate 6. With sufficient precision, a smooth connection can be achieved. This design guides rainwater to drain along the guide surface, reducing water accumulation and penetration between the photovoltaic laminate 6 and the first frame 5, and minimizing the impact of rainwater on the sealing strip 4. The sealing strip 4 is configured with multiple sealing protrusions and slits to achieve a multi-level sealing effect. When rainwater passes through the first layer of sealing protrusions, it enters the first slit. Under capillary action, water vapor is trapped in the slit and eliminated through natural evaporation, thus reducing penetration to the second layer of sealing protrusions. In this embodiment, the multi-level sealing design significantly reduces rainwater permeability and improves the sealing effect. This multi-level sealing design with the guide surface significantly improves the actual sealing effect.

[0041] In this embodiment, a plurality of reinforcing ribs 181 are provided inside the rectangular frame 18. The reinforcing ribs 181 are distributed on the upper and lower sides of the rectangular frame 18 and are arranged parallel to the length direction of the rectangular frame 18 to improve the strength of the rectangular frame 18. A plurality of material reduction grooves 19 are arranged parallel to the length direction of the second frame 1, which reduces the weight and improves the strength. An overflow groove 52 is provided on the first frame 5. These structures are conventional designs, and the specific settings can be adjusted by those skilled in the art as needed.

[0042] The basic principles, main features, and advantages of this application have been described above. Those skilled in the art should understand that this application is not limited to the above embodiments. The embodiments and descriptions in the specification are merely the principles of this application. Various changes and modifications can be made to this application without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claims. The scope of protection claimed by this application is defined by the appended claims and their equivalents.

Claims

1. A single-glass module with a multi-layer composite weather-resistant encapsulation structure, characterized in that, include: A photovoltaic module, comprising a photovoltaic laminate and a first frame, wherein the photovoltaic laminate is edge-covered by the first frame, and a sealing silicone sealant is filled between the photovoltaic laminate and the first frame; a frame assembly, comprising a second frame, a top plate, an elastic element, and a sealing strip, wherein the second frame is provided with a communicating first mounting cavity and a second mounting cavity, the first frame is inserted into the first mounting cavity, the top plate is movably disposed in the second mounting cavity, the elastic element is disposed between the top plate and the bottom surface of the second mounting cavity, the top plate is tightly abutted against the first frame by the elastic force of the elastic element, and the sealing strip is disposed at the opening of the first mounting cavity, wherein after the photovoltaic module is inserted into the frame assembly, the sealing strip seals against the photovoltaic laminate.

2. A monolithic glass unit having a multi-layered composite weatherable packaging structure according to claim 1, wherein, The second frame includes an integrally formed rectangular frame, a first vertical plate, a second vertical plate, and an upper horizontal plate. The first vertical plate is disposed on the upper left side of the rectangular frame, the upper horizontal plate is disposed on the upper end of the first vertical plate, and the second vertical plate is disposed on the upper right side of the rectangular frame. An opening for the first mounting cavity is formed between the right end of the upper horizontal plate and the upper end of the second vertical plate. A first stop strip is integrally formed on the right side of the first vertical plate, and a second stop strip is integrally formed on the left side of the second vertical plate. The first mounting cavity is formed between the first stop strip, the second stop strip, and the upper horizontal plate, and the second mounting cavity is formed between the first stop strip, the second stop strip, and the rectangular frame.

3. A single-glass module with a multi-layer composite weather-resistant encapsulation structure as described in claim 2, characterized in that, The bottom surface of the second mounting cavity is provided with a plurality of second mounting slots. The elastic element is a disc spring, which is embedded in the second mounting slot. The lower side of the top plate abuts against the disc spring. In its natural state, the disc spring is in a preliminary compressed state. The top plate moves upward under the elastic force of the disc spring until its two sides abut against the lower sides of the first stop bar and the second stop bar, respectively. The upper part of the top plate extends into the first mounting cavity. When the first frame is inserted into the first mounting cavity, the first frame squeezes the top plate to move it downward, further compressing the disc spring. Under the elastic force of the disc spring, the top plate abuts tightly against the first frame.

4. A single-glass module with a multi-layer composite weather-resistant encapsulation structure as described in claim 2, characterized in that, The lower side of the upper horizontal plate is provided with a positioning protrusion, and the first frame is provided with a corresponding positioning groove. After the first frame is inserted into the first mounting cavity, the positioning protrusion and the positioning groove are connected.

5. A single-glass module with a multi-layer composite weather-resistant encapsulation structure as described in claim 2, characterized in that, The upper horizontal plate has a protective part at its right end, and a first mounting groove is provided on the side of the protective part facing the photovoltaic laminate. The upper end of the second vertical plate also has a first mounting groove. A sealing strip is fixedly installed in the first mounting groove. After the photovoltaic module is inserted into the frame assembly, the sealing strip abuts tightly against the photovoltaic laminate.

6. A single-glass module with a multi-layer composite weather-resistant encapsulation structure as described in claim 5, characterized in that, The outer surface of the protective part is a sloped surface or an inclined curved surface. After the photovoltaic module is inserted into the frame assembly, the outer surface of the protective part transitions and joins with the surface of the photovoltaic laminate to form a flow guiding surface.

7. A single-glass module with a multi-layer composite weather-resistant encapsulation structure as described in claim 1, characterized in that, The sealing strip has several sealing protrusions arranged in parallel to form a multi-level seal. There are narrow gaps between the sealing protrusions. If water vapor accidentally passes through the sealing protrusions, it will be trapped in the narrow gaps due to capillary action.

8. A single-glass module with a multi-layer composite weather-resistant encapsulation structure as described in claim 2, characterized in that, The rectangular frame has a number of reinforcing ribs inside, which are distributed on the upper and lower sides of the rectangular frame and are arranged parallel to the length of the rectangular frame.

9. A single-glass module with a multi-layer composite weather-resistant encapsulation structure as described in claim 1, characterized in that, Several material reduction grooves are arranged parallel to each other along the length of the second frame.

10. A single-glass module with a multi-layer composite weather-resistant encapsulation structure as described in claim 1, characterized in that, An overflow groove is provided on the first frame.

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