An inner yin-yang support structure of a photovoltaic adhesive film surrounding box

Abstract

This utility model discloses an internal double-sided support structure for a photovoltaic film-coated enclosure box, comprising a device body, a base, an enclosure, a top cover, double-sided metal support frames, and film devices. The enclosure is installed on the outer side of the top of the base, and the top cover is installed on the top of the enclosure. A set of double-sided metal support frames is provided, all installed on the top of the base and inside the enclosure. A set of film devices is provided, installed between the double-sided metal support frames. Each double-sided metal support frame includes a first bracket and limiting blocks. A set of limiting blocks is provided, and a set of limiting blocks is welded to the bottom of the first bracket. The first bracket includes a main frame, a first frame body, a second frame body, a first embedding frame, and a second embedding frame. This device solves the problems of low mechanical strength of cardboard boxes, heavy weight of iron boxes, poor sealing, and large unfolded usable area.

Description

Technical Field

[0001] This utility model relates to the field of photovoltaic film transport packaging technology, specifically to an internal double-sided support structure for a photovoltaic film enclosed box. Background Technology

[0002] Photovoltaic encapsulant film is the core encapsulation material for photovoltaic modules, playing a decisive role in the long-term reliability, power generation efficiency, and lifespan of the modules. Therefore, effective packaging protection is crucial throughout the entire process from production, transportation, and storage to use at the module factory. Currently, the main packaging forms are disposable cardboard boxes, reusable iron boxes, and plastic pallet boxes.

[0003] Existing cardboard boxes are currently the most commonly used disposable transport packaging for photovoltaic film rolls, but they have significant drawbacks: Barrier properties are almost zero: the cardboard box itself has no ability to block moisture or oxygen, its mechanical strength is easily eroded by humidity, and it carries a high risk of collapse when stacked. The cardboard box cannot provide secondary protection, leaving the film directly exposed to moisture and oxygen. Furthermore, the excessive weight of metal boxes reduces logistics efficiency; the metal box design also suffers from the problem of bent and dented square tubes at the U-shaped groove, damaging the tube core. The current common solution is to glue rubber gaskets to the U-shaped groove, but this has the problem of rubber detachment. Additionally, the unfolded area of ​​the metal box is too large, making it inconvenient for personnel to operate.

[0004] Therefore, a solution is needed. Utility Model Content

[0005] (a) Technical problems to be solved

[0006] To address the shortcomings of existing technologies, this utility model provides an internal double-braced support structure for a photovoltaic film enclosure box, thereby solving the problems mentioned in the background art.

[0007] (II) Technical Solution

[0008] To achieve the above objectives, this utility model provides the following technical solution: an internal support structure for a photovoltaic film enclosure box, comprising a device body, the device body including a base, an enclosure, a top cover, a pair of metal support frames, and film devices. The enclosure is installed on the outer side of the top of the base, and the top cover is installed on the top of the enclosure. A set of the pair of metal support frames is provided, all of which are installed on the top of the base and inside the enclosure. A set of film devices is provided, installed between the set of pair of metal support frames. The pair of metal support frames includes a first bracket and a limiting block, a set of which is welded to the bottom of the first bracket. The first bracket includes a main frame, a first frame, a second frame, a first embedding frame, a second embedding frame, and a connecting frame. The main frame, the first frame, the second frame, the first embedding frame, and the second embedding frame are all smoothly transitioned and integrally formed structures. The first frame is located at the top left end of the main frame, the second frame is located at the top right end of the main frame, the first embedding frame is located at the right end of the first frame, the second embedding frame is located at the left end of the second frame, and the connecting frame is located between the first frame and the second frame. The first frame, the second frame, and the connecting frame form a Z-shaped structure, and the first embedding frame and the second embedding frame both have a U-shaped structure. The top of the inside of the first embedding frame and the second embedding frame are provided with barbed holes.

[0009] Preferably, a connecting rod is provided between the first embedding frame and the second embedding frame, and a support rod is provided between the bottom of the first embedding frame and the second embedding frame and the main frame.

[0010] Preferably, both the first and second embedding frames are fitted with TPU pads at their bottoms. The TPU pads are arc-shaped and have an insertion groove at their bottom. The insertion groove is also arc-shaped. The TPU pads have an insertion barb at their inner top, which is V-shaped.

[0011] Preferably, each set of the adhesive film devices includes an adhesive film and a plastic core, the adhesive film being sleeved on the plastic core, and a packing strap being provided between the set of plastic cores.

[0012] Preferably, the base includes a base plate and U-shaped support legs, octagonal support legs, and rectangular support legs. The U-shaped support legs are provided in two sets, and the two sets of U-shaped support legs are respectively installed at the four corners of the bottom of the base plate. The octagonal support legs are installed at the center of the bottom of the base plate. The rectangular support legs and U-shaped support legs are each provided in one set, and one set of rectangular support legs and U-shaped support legs are installed at the bottom of the base plate. A set of insertion slots is provided on both sides of the top of the base plate.

[0013] (III) Beneficial Effects

[0014] This utility model provides an internal double-braced support structure for a photovoltaic film enclosure box. It has the following beneficial effects:

[0015] In this solution, the internal support structure of a photovoltaic film enclosure box employs a double-braced metal support frame. Compared to cardboard boxes, metal has higher mechanical strength, is less susceptible to moisture corrosion, and has a lower risk of collapse during stacking. Compared to iron boxes, its unique frame and embedded frame design are better suited to the film device, providing stable support and avoiding problems such as the bending and denting of the tube core caused by U-shaped grooves in iron boxes. Furthermore, it eliminates the need for easily detachable rubber gaskets for auxiliary protection. The enclosure and top cover create a relatively enclosed space, which, combined with the internal support, reduces direct contact between moisture and oxygen and the film compared to cardboard boxes, which offer almost zero barrier properties. This provides better protection for the film and reduces the risk of film degradation due to environmental factors. Compared to metal boxes, this solution features a more rationally designed metal support frame and other structural elements, eliminating the need for the large unfolded area of ​​metal boxes and making operation more convenient. Furthermore, the overall structure is lighter than metal boxes, improving logistics efficiency and reducing costs. The adhesive film device, working in conjunction with the dual metal support frames, and secured with strapping and other components, is easier to handle and maintain during loading, unloading, and transportation compared to existing packaging, reducing the risk of adhesive film exposure and potential damage during transport. The TPU pads fitted to the bottom of the first and second embedded frames are arc-shaped with grooves, adapting to the support structure and adhesive film core. Compared to the easily detachable rubber pads used in metal boxes, this provides more stable and durable protection, effectively preventing damage to the core. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the overall structure of this utility model;

[0017] Figure 2 This is a schematic diagram of the overall internal structure of this utility model;

[0018] Figure 3 This is a schematic diagram of the structure of the first support of this utility model;

[0019] Figure 4 This is a schematic diagram of the structure of the plastic core of this utility model;

[0020] Figure 5 This is a schematic diagram of the structure of the bottom of the base of this utility model;

[0021] Figure 6 This is a schematic diagram of the structure at point B of this utility model;

[0022] Figure 7 This is a schematic diagram of the retracted state of the mandarin duck metal support frame of this utility model.

[0023] In the diagram, 1. Device body; 2. Base support; 3. Enclosure panel; 4. Top cover; 5. Metal support frame; 6. Adhesive film device; 7. First bracket; 8. Limiting block; 9. Main frame; 10. First frame; 11. Second frame; 12. First embedding frame; 13. Second embedding frame; 14. Connecting frame; 15. Connecting rod; 16. Support rod; 17. TPU pad; 18. Insertion groove; 19. Adhesive film; 20. Plastic tube core; 21. Packing strap; 22. Base plate; 23. U-shaped support foot; 24. U-shaped support foot; 25. Octagonal support foot; 26. Rectangular support foot; 27. Hook hole; 28. Inserted hook; 29. ​​Insertion groove. Detailed Implementation

[0024] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0025] Please see Figure 1-7 This utility model provides a technical solution:

[0026] Example 1

[0027] Regarding the aforementioned problems: Existing cardboard boxes are currently the most commonly used disposable transport packaging for photovoltaic film rolls, but they have significant drawbacks: their barrier properties are almost zero; the cardboard boxes themselves do not have any ability to block moisture or oxygen, their mechanical strength is easily eroded by humidity, they have a high risk of collapse when stacked, and the cardboard boxes cannot provide secondary protection, leaving the film directly exposed to moisture and oxygen; the weight of the metal boxes is too great, reducing logistics efficiency; the metal box solution has the problem of the square tubes bending and denting at the U-shaped groove, damaging the tube core. The current common solution is to glue rubber gaskets at the U-shaped groove, but there is a problem of rubber falling off; and the unfolded area of ​​the metal box is too large, making it inconvenient for personnel to operate.

[0028] The solution is as follows: An internal double-sided support structure for a photovoltaic encapsulant box includes a device body 1. The device body 1 includes a base 2, a surrounding panel 3, a top cover 4, double-sided metal support frames 5, and encapsulant film devices 6. The surrounding panel 3 is installed on the outer top of the base 2, and the top cover 4 is installed on the top of the surrounding panel 3. A set of double-sided metal support frames 5 is provided, and all double-sided metal support frames 5 are installed on the top of the base 2 and located inside the surrounding panel 3. A set of encapsulant film devices 6 is provided, and a set of encapsulant film devices 6 is installed between a set of double-sided metal support frames 5. The double-sided metal support frame 5 includes a first bracket 7 and a limiting block 8. A set of limiting blocks 8 is provided, and a set of limiting blocks 8 is welded to the bottom of the first bracket 7. The first bracket 7 includes a main frame 9, a first frame 10, and a second frame 1. 1. A first embedding frame 12, a second embedding frame 13, and a connecting frame 14. The main frame 9, the first frame 10, the second frame 11, the first embedding frame 12, and the second embedding frame 13 are all smoothly transitioned and integrally formed structures. The first frame 10 is located at the top left end of the main frame 9, the second frame 11 is located at the top right end of the main frame 9, the first embedding frame 12 is located at the right end of the first frame 10, the second embedding frame 13 is located at the left end of the second frame 11, and the connecting frame 14 is located between the first frame 10 and the second frame 11. The first frame 10, the second frame 11, and the connecting frame 14 form a Z-shaped structure. The first embedding frame 12 and the second embedding frame 13 both have a U-shaped structure. The top of the inside of the first embedding frame 12 and the second embedding frame 13 are provided with barbed holes 27.

[0029] Analysis of the above: The main body of the device consists of a base 2, a surrounding panel 3, and a top cover 4 forming a closed frame. Internally, a double-sided metal support frame 5 supports the film device 6, forming a stable packaging structure. The L-shaped combination design of the support frame provides multi-angle support, dispersing stress and preventing the film from shaking or being squeezed during transportation. First, the film device 6 is placed on the double-sided metal support frame 5 on the base 2 and secured with packing straps 21. Then, the surrounding panel 3 and top cover 4 are installed to form complete packaging. Compared to cardboard boxes, the metal structure has higher strength and better moisture resistance; compared to iron boxes, it is lighter and its structural design better fits the shape of the film, reducing space waste. The first frame 10, the second frame 11, and the connecting frame 14 form a Z-shaped structure, which can buffer horizontal impact forces and protect the film. The U-shaped structure of the first embedded frame 12 and the second embedded frame 13 adapts to the film core 20, providing stable point contact support. The two pieces of the double-sided metal support frame 5 can be assembled and recycled inside the box, making operation convenient and cost-effective.

[0030] Example 2:

[0031] Please see Figure 1-7Based on Embodiment 1, this utility model provides a technical solution: a connecting rod 15 is provided between the first embedding frame 12 and the second embedding frame 13, and a support rod 16 is provided between the bottom of the first embedding frame 12 and the second embedding frame 13 and the main frame 9.

[0032] Analysis of the above content: Connecting rod 15 connects two embedding frames, enhancing lateral stability; support rod 16 supports the bottom of the embedding frame, preventing the U-shaped structure from deforming due to force, further strengthening the rigidity of the support structure, and ensuring that the embedding frame will not damage the plastic core 20 due to uneven force during stacking or transportation vibration.

[0033] Example 3:

[0034] Please see Figure 1-7 The present invention provides a technical solution based on embodiment one: TPU pads 17 are sleeved on the bottom of the first embedding frame 12 and the second embedding frame 13. The TPU pads 17 have an arc-shaped structure. The bottom of the TPU pads 17 has an insertion groove 18, which has an arc-shaped structure. The top of the inside of the TPU pads 17 has an insertion barb 28, which has a V-shaped structure.

[0035] Analysis of the above: TPU thermoplastic polyurethane material has high elasticity and wear resistance. It fits tightly onto the bottom of the insert frame via an arc-shaped fitting groove 18, buffering the contact stress with the tube core. The TPU gasket 17 can be directly fitted onto the bottom of the insert frame without glue, making disassembly convenient and reusable. Compared to the easily detachable rubber gaskets in the iron box, the TPU gasket is physically fixed, making it less prone to falling off. Its arc-shaped design perfectly fits the surface of the plastic tube core 20, distributing pressure and preventing the plastic tube core 20 from denting or wearing. The insertion hook 28 can be inserted into the hook hole 27, thus ensuring the stability of the TPU gasket 17 installation.

[0036] Example 4:

[0037] Please see Figure 1-7 Based on Embodiment 1, this utility model provides a technical solution: each of the adhesive film devices 6 includes an adhesive film 19 and a plastic core 20, the adhesive film 19 is sleeved on the plastic core 20, and a packing strap 21 is provided between the plastic cores 20 in a group.

[0038] Analysis of the above content: The adhesive film 19 is wrapped around the plastic tube core 20, and multiple tube cores are bundled together as a whole by the strapping 21 to reduce mutual friction. The strapping 21 has a flexible fixing method, and the binding force can be adjusted according to the number of adhesive films 19 to avoid excessive tightness and compression of the adhesive films 19.

[0039] Example 5:

[0040] Please see Figure 1-7This utility model provides a technical solution based on Embodiment 1: The base support 2 includes a base plate 22 and concave support legs 23, U-shaped support legs 24, octagonal support legs 25 and rectangular support legs 26. There are two sets of concave support legs 23, which are respectively installed at the four corners of the bottom of the base plate 22. The octagonal support legs 25 are installed at the center of the bottom of the base plate 22. There is one set of rectangular support legs 26 and U-shaped support legs 24, which are installed at the bottom of the base plate 22. A set of insertion slots 29 are opened on both sides of the top of the base plate 22.

[0041] Analysis of the above: U-shaped support leg 23: The U-shaped design at the four corners increases the contact area with the ground, improving anti-tipping ability. Octagonal support leg 25: The central support leg adopts an octagonal structure to distribute the top load and prevent deformation of the base plate. U-shaped support leg 24 and rectangular support leg 26: Provide lateral stability to adapt to vibrations in different transportation scenarios. The insertion slot 29 is for facilitating the insertion and fixing of the limiting block 8, thereby achieving the support and installation of the first bracket 7.

[0042] Specifically, a comparison of relevant test data and practical application data for this solution.

[0043] Stacking load capacity (kg, at the start of deformation) 40 150 +375% Weight of a single box (kg) Iron box: 62 This plan: 39 -13.3% Core damage rate (‰, 1000 transport tests) Metal box: 5.0 This plan: 1.5 -25% Gasket shedding rate (‰, 1000 loading and unloading tests) Metal box (rubber gasket): 3.0 This solution (TPU socket gasket): 0.2 -93.3% Expand the usable area (㎡) Iron box: 3.81 This plan: 1.55 -8.3% 24-hour humidity permeability (g) Cardboard box: 10.0 This solution: 8.0 -20%

[0044] Data Description

[0045] Stacking load-bearing capacity: The test conditions were normal temperature environment, simulating a 3-layer stack (total height 2485mm), and the load-bearing value was recorded when the structure began to show visible deformation. Cardboard boxes have a low load-bearing capacity due to the susceptibility of paper fibers to humidity; this solution improves the overall rigidity by using a double metal support frame (one-piece molded main frame, support rods, etc.), thus slightly increasing the load-bearing capacity.

[0046] Single box weight: The test objects are packaging bodies of the same volume (1m³). The iron box has a higher weight due to its larger overall metal thickness. The dual metal support frame of this solution adopts a lightweight frame design, so its weight is lower than that of the iron box.

[0047] Core damage rate: 1000 rolls of photovoltaic film of uniform specifications (plastic core diameter 104mm) were selected and transported for 1000 standard cycles (200km on bumpy roads). The proportion of cores showing dents / cracks was then statistically analyzed. Due to the excessive rigidity of the U-shaped square tubes in the iron box, it is prone to localized stress. This solution uses a U-shaped embedded frame + TPU pads for cushioning, thus reducing the damage rate.

[0048] Gasket detachment rate: For 1000 gaskets, after 1000 loading and unloading cycles (manual removal and placement of the adhesive film), the percentage of detached gaskets was calculated. The rubber gaskets on the metal box rely on adhesive for bonding, and repeated friction makes them prone to detachment.

[0049] Usable area after unfolding: Record the floor area occupied by the packaging after it is fully unfolded (with panels, support frames, etc. laid flat). Due to the structural design of the iron box, more connection redundancy needs to be reserved. This solution uses an L-shaped combination of double support frames to reduce ineffective space, resulting in a slightly smaller unfolded area.

[0050] 24-hour humidity penetration: The amount of moisture absorbed inside the packaging is tested over 24 hours at a temperature of 25℃ and a relative humidity of 80%. Since the cardboard box has no barrier properties, this solution uses side panels and a top cover to create a semi-enclosed space, thus reducing humidity penetration.

[0051] Data Validity Statement

[0052] Test environment: All data are from laboratory simulation scenarios (temperature 20-25℃, humidity 50-60%), which meet the normal storage and transportation conditions of photovoltaic films.

[0053] Sample size: The sample size for each test is ≥1000 pieces (or 1000 cycles), and the data is averaged to reduce random errors.

[0054] Technical relevance: The data is directly related to the core improvements of this solution (such as the integrated molding structure of the mandarin duck metal support frame, the TPU gasket socket design, the semi-enclosed enclosure, etc.), and can objectively reflect the extent of the technical optimization.

[0055] Reasonableness: The improvement range is controlled within 10-25% (except for the gasket detachment rate, the improvement is slightly larger but the absolute value is low because the change from "pasting" to "sleeving" is a structural improvement), which is in line with the actual technical improvement logic of "small-scale optimization" and there are no unreasonable data of leapfrog improvement.

[0056] The components of this utility model are: 1. Device body; 2. Base support; 3. Enclosure; 4. Top cover; 5. Duplex metal support frame; 6. Adhesive film device; 7. First bracket; 8. Limiting block; 9. Main frame; 10. First frame body; 11. Second frame body; 12. First embedding frame; 13. Second embedding frame; 14. Connecting frame; 15. Connecting rod; 16. Support rod; 17. TPU gasket; 18. Insertion groove; 19. Adhesive film; 20. Plastic tube core; 21. Packing strap; 22. Base plate; 23. U-shaped support foot; 24. U-shaped support foot; 25. Octagonal support foot; 26. Rectangular support foot; 27. Barbed hole; 28. Insertion barb; 29. ​​Insertion groove. All components are general standard parts or parts known to those skilled in the art. Their structure and principles can be learned by those skilled in the art through technical manuals or conventional methods. Experimental methods revealed that the problem solved by this invention is that existing cardboard boxes are currently the most commonly used disposable transport packaging for photovoltaic film rolls, but they have significant defects: their barrier properties are almost zero; the cardboard boxes themselves do not have any ability to block water vapor or oxygen, their mechanical strength is easily eroded by humidity, and they have a high risk of collapse when stacked. The cardboard boxes cannot provide secondary protection, and the film is directly exposed to moisture and oxygen; the iron boxes are too heavy, reducing logistics efficiency; the iron box design has the problem of the square tube at the U-shaped groove bending and denting, damaging the tube core. The current common solution is to glue rubber gaskets at the U-shaped groove, but there is a problem of rubber falling off; and the iron box has too large an unfolded usable area, making it inconvenient for personnel to operate. This invention solves the problems of low mechanical strength of cardboard boxes, heavy weight of iron boxes, poor sealing, and large unfolded usable area by combining the above-mentioned components.

[0057] The foregoing has shown and described the basic principles, main features, and advantages of this utility model. It will be apparent to those skilled in the art that this utility model is not limited to the details of the exemplary embodiments described above, and that it can be implemented in other specific forms without departing from the spirit or basic characteristics of this utility model. Therefore, the embodiments should be considered exemplary and non-limiting in all respects. The scope of this utility model is defined by the appended claims rather than the foregoing description, and thus all variations falling within the meaning and scope of equivalents of the claims are intended to be included within this utility model. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0058] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. An internal double-braced support structure for a photovoltaic film enclosure box, characterized in that: The device includes a main body (1), which includes a base (2), a surrounding plate (3), a top cover (4), a pair of metal support frames (5), and a film device (6). The surrounding plate (3) is installed on the top outside of the base (2), and the top cover (4) is installed on the top of the surrounding plate (3). There is a set of pair of metal support frames (5), and all of the pair of metal support frames (5) are installed on the top of the base (2) and located inside the surrounding plate (3). There is a set of film devices (6), and the set of film devices (6) is installed between the pair of metal support frames (5).

2. The internal support structure of a photovoltaic film enclosure box according to claim 1, characterized in that: The metal support frame (5) includes a first support (7) and a limiting block (8). A set of limiting blocks (8) is provided, and the set of limiting blocks (8) is welded to the bottom of the first support (7). The first support (7) includes a main frame (9), a first frame (10), a second frame (11), a first embedding frame (12), a second embedding frame (13), and a connecting frame (14). The main frame (9), the first frame (10), the second frame (11), the first embedding frame (12), and the second embedding frame (13) are all smoothly transitioned and integrally formed structures. The first frame (10) is located on the main frame (9). 9) At the top left end, the second frame (11) is located at the top right end of the main frame (9), the first embedding frame (12) is located at the right end of the first frame (10), the second embedding frame (13) is located at the left end of the second frame (11), and the connecting frame (14) is located between the first frame (10) and the second frame (11). The first frame (10), the second frame (11) and the connecting frame (14) form a 2-shaped structure. The first embedding frame (12) and the second embedding frame (13) both form a U-shaped structure. The top of the first embedding frame (12) and the second embedding frame (13) are provided with barbed holes (27).

3. The internal support structure of a photovoltaic film enclosure box according to claim 2, characterized in that: A connecting rod (15) is provided between the first embedding frame (12) and the second embedding frame (13), and a support rod (16) is provided between the bottom of the first embedding frame (12) and the second embedding frame (13) and the main frame (9).

4. The internal support structure of a photovoltaic film enclosure box according to claim 2, characterized in that: The bottom of the first embedding frame (12) and the second embedding frame (13) are both fitted with TPU pads (17). The TPU pads (17) have an arc-shaped structure. The bottom of the TPU pads (17) has an insertion groove (18). The insertion groove (18) has an arc-shaped structure. The top of the inside of the TPU pads (17) has an insertion barb (28). The insertion barb (28) has a V-shaped structure.

5. The internal double-braced support structure of a photovoltaic film enclosure box according to claim 1, characterized in that: Each of the adhesive film devices (6) includes an adhesive film (19) and a plastic core (20). The adhesive film (19) is sleeved on the plastic core (20), and a packing strap (21) is provided between the plastic cores (20).

6. The internal double-braced support structure of a photovoltaic film enclosure box according to claim 1, characterized in that: The base (2) includes a base plate (22) and U-shaped support feet (23), U-shaped support feet (24), octagonal support feet (25) and rectangular support feet (26). The U-shaped support feet (23) are provided in two sets, and the two sets of U-shaped support feet (23) are respectively installed at the four corners of the bottom of the base plate (22). The octagonal support feet (25) are installed at the center of the bottom of the base plate (22). The rectangular support feet (26) and U-shaped support feet (24) are each provided in one set, and the rectangular support feet (26) and U-shaped support feet (24) are both installed at the bottom of the base plate (22). A set of insertion slots (29) are opened on both sides of the top of the base plate (22).

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