Edge protectors, photovoltaic modules and edge protector manufacturing equipment

Abstract

This utility model relates to the field of photovoltaic module technology, and discloses an edge protector, a photovoltaic module, and an edge protector manufacturing apparatus. The edge protector includes a substrate and a hot melt adhesive layer. The substrate includes a bottom wall and a side wall. The bottom wall supports the backlight surface of the laminate in the height direction, and the side wall is connected to one end of the bottom wall in the width direction to abut against the side of the laminate. The hot melt adhesive layer is located on the same side of the bottom wall in the height direction as the side wall and covers the surface of the bottom wall. The edge protector uses hot melt adhesive as the bonding material to the laminate, and the hot melt adhesive is pre-formed together with the substrate in the form of a hot melt adhesive layer. The edge protector and the laminate are laminated together, thereby bonding the edge protector and the laminate while forming the laminate. This eliminates the need for applying adhesive to the edge protector and assembling the edge protector after lamination, helping to reduce the assembly cost of photovoltaic modules.

Description

Technical Field

[0001] This utility model relates to the field of photovoltaic module technology, specifically to edge protection, photovoltaic modules, and edge protection manufacturing device. Background Technology

[0002] Photovoltaic modules typically have frames to prevent damage or even breakage of the laminated components due to collisions and friction. In related technologies, frame installation is generally carried out after the laminated components are laminated, using either a frame assembly machine or manual assembly. This process is cumbersome, resulting in high assembly costs. Utility Model Content

[0003] In view of this, the present invention provides an edge protector, a photovoltaic module, and an edge protector manufacturing device to solve the problem of high assembly cost of photovoltaic modules.

[0004] In a first aspect, the present invention provides an edge protector having a length direction, a width direction, and a height direction. The edge protector extends in the length direction and includes a substrate and a hot melt adhesive layer. The substrate includes a bottom wall and a side wall. The bottom wall is used to support the backlight surface of the laminate in the height direction. The side wall is connected to one end of the bottom wall in the width direction and is used to abut against the side of the laminate. The hot melt adhesive layer is located on the same side of the bottom wall in the height direction as the side wall and covers the surface of the bottom wall.

[0005] Beneficial effects: Hot melt adhesive is used as the bonding material for the edge protector and the laminate. The hot melt adhesive is prefabricated together with the substrate in the form of a hot melt adhesive layer. When assembling photovoltaic modules, the raw materials of the laminate are stacked on the edge protector, and the edge protector and the laminate are laminated together. This allows the edge protector and the laminate to be bonded together while the laminate is being formed, eliminating the need for applying adhesive to the edge protector and assembling the edge protector after lamination. This helps to reduce the assembly cost of photovoltaic modules.

[0006] In one alternative embodiment, the bottom wall is provided with an adhesive storage tank, and the hot melt adhesive layer is at least partially located within the adhesive tank.

[0007] Beneficial effects: The hot melt adhesive layer filling the glue tank helps to increase the volume of the hot melt adhesive layer, so that it can fill the gap between the substrate and the laminate more fully during lamination, making the edge protection more tightly and reliably bonded to the laminate.

[0008] In one alternative embodiment, the sidewall is provided with an overflow groove.

[0009] Beneficial effects: During the lamination process, the molten hot melt adhesive layer overflows to all sides under the pressure of the laminate. Some of the hot melt adhesive flows between the sidewall and the side of the laminate, causing the sidewall and the side of the laminate to bond together. The overflow groove can store hot melt adhesive, thereby increasing the volume of hot melt adhesive between the sidewall and the laminate and improving the tightness of the bond.

[0010] In one alternative embodiment, in the width direction, the depth of the glue reservoir gradually decreases from the end closer to the sidewall to the end farther away from the sidewall.

[0011] Beneficial effects: By using an inclined adhesive reservoir, more molten hot melt adhesive can be guided to flow towards the sidewall, thereby increasing the amount of adhesive flowing between the sidewall and the side of the laminate, and improving the tightness of the bond between the sidewall and the side of the laminate.

[0012] In one optional embodiment, the substrate is made of a metallic material or a non-metallic material, wherein the metallic material includes aluminum alloy, and the non-metallic material includes any one of nylon, polyphenylene ether, polyethylene, polypropylene, and polyvinyl chloride.

[0013] Beneficial effects: Different materials can be selected for the substrate, thereby meeting the needs of different photovoltaic modules.

[0014] In one alternative embodiment, the hot melt adhesive layer is made of ethylene-vinyl acetate copolymer.

[0015] Beneficial effects: Ethylene-vinyl acetate copolymer has good weather resistance and adhesion, can reliably connect substrates and laminates, and can withstand harsh outdoor environments, thus improving the service life of edge protectors.

[0016] Secondly, this utility model provides a photovoltaic module, including a photovoltaic frame and a laminate. The photovoltaic frame includes the edge protector provided by this utility model, and multiple edge protectors enclose an installation space. The laminate is disposed on the photovoltaic frame, and the photovoltaic frame and the laminate are integrally laminated.

[0017] Beneficial effects: The photovoltaic module includes the edge protection provided by this utility model, and therefore has the corresponding beneficial effects brought about by the edge protection, which will not be elaborated here.

[0018] In one alternative embodiment, the light-facing surface of the laminate is higher than or flush with the sidewall.

[0019] Beneficial effects: When the light-facing surface is higher than or flush with the sidewall, it can prevent water and dust accumulation between the sidewall and the laminate, reducing interference with the power generation capacity of the laminate.

[0020] In one alternative embodiment, the photovoltaic frame further includes corner protectors connected between two adjacent edge protectors.

[0021] Beneficial effects: Using corner protectors to connect the edge protectors allows for pre-positioning of the edge protectors before lamination, improving the positional accuracy of the edge protectors. In addition, the corner protectors can enhance the strength of the photovoltaic frame at the corners and improve its impact resistance.

[0022] Thirdly, this utility model also provides an edge protection manufacturing device for manufacturing the edge protection provided by this utility model, including an extruder, a first shaping machine, a glue coating machine, and a second shaping machine. The extruder is used to extrude and shape the substrate. The first shaping machine is located downstream of the extruder and is used to cool and shape the substrate. The glue coating machine is located downstream of the first shaping machine and is used to coat the bottom wall with a hot melt adhesive layer. The second shaping machine is located downstream of the glue coating machine and is used to cool and cure the hot melt adhesive layer.

[0023] Beneficial effects: The edge protection device is used to make the edge protection provided by this utility model, and therefore has the corresponding beneficial effects brought about by edge protection, which will not be elaborated here. Attached Figure Description

[0024] To more clearly illustrate the specific embodiments of this utility model or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0025] Figure 1 This is a schematic diagram of the edge protection structure according to an embodiment of the present utility model;

[0026] Figure 2 This is a schematic diagram of the assembly of an edge protector according to an embodiment of the present utility model, which shows the stacking method of the edge protector and the laminate;

[0027] Figure 3 This is a top view of a photovoltaic module according to an embodiment of the present utility model;

[0028] Figure 4 This is a bottom view of a photovoltaic module according to an embodiment of the present utility model;

[0029] Figure 5 This is an exploded view of a photovoltaic module according to an embodiment of the present invention;

[0030] Figure 6 This is a schematic diagram of the structure of a edging production device according to an embodiment of the present utility model.

[0031] Explanation of reference numerals in the attached figures:

[0032] 1. Edge protector; 101. Substrate; 1011. Bottom wall; 1012. Side wall; 1013. Glue overflow groove; 102. Hot melt adhesive layer; 2. Laminated component; 3. Corner protector; 401. Extruder; 402. First setting machine; 403. Glue spreading machine; 404. Second setting machine; 405. Cutting machine. Detailed Implementation

[0033] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0034] It should be understood that the terminology used herein is for the purpose of describing particular exemplary embodiments only and is not intended to be limiting. Unless the context clearly indicates otherwise, the singular forms "a," "an," and "comprising" as used herein may also mean including the plural forms. The terms "comprising," "including," and "having" are inclusive and therefore indicate the presence of the stated features, elements, and / or components, but do not exclude the presence or addition of one or more other features, elements, components, and / or combinations thereof.

[0035] Although terms such as "first," "second," etc., may be used in this document to describe multiple elements, components, regions, layers, and / or segments, these elements, components, regions, layers, and / or segments should not be limited by these terms. These terms may be used only to distinguish one element, component, region, layer, or segment from another. Unless the context clearly indicates otherwise, terms such as "first," "second," and other numerical terms used herein do not imply order or sequence. Furthermore, in the description of this utility model, unless otherwise expressly specified and limited, the terms "set up" and "connected" should be interpreted broadly; for example, they may refer to a fixed connection, a detachable connection, or an integral connection; they may refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art will understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0036] For ease of description, spatial relative terms may be used in the text to describe the relationship of one element or feature relative to another element or feature, as shown in the figure. These relative terms include, for example, "end," "length," "inner," "outer," etc. Such spatial relative terms are intended to include different orientations of the mechanism in use or operation, in addition to those depicted in the figure. For example, if the mechanism in the figure is flipped, an element described as "below other elements or features" or "below other elements or features" would subsequently be oriented as "above other elements or features" or "above other elements or features." Therefore, the example term "below" can include both upper and lower orientations. The mechanism may be otherwise oriented (rotated 90 degrees or in other directions), and the spatial relative descriptors used in the text will be interpreted accordingly.

[0037] When assembling photovoltaic modules using the frame assembly process, the first step is to laminate the components. Then, adhesive is applied to the two sets of frames (first frame and second frame). Next, the first frame is placed opposite each other, the laminate is placed on the first frame and pressure is applied to fill the gap between the first frame and the laminate with adhesive. Finally, the second frame is pushed from both sides towards the first frame to close with the first frame and form a frame, and adhesive is applied to fill the gap between the second frame and the laminate.

[0038] The frame assembly process is relatively complex and the assembly cost is high.

[0039] The following is combined Figures 1 to 6 The following describes embodiments of the present invention.

[0040] Reference Figure 1 , Figure 2 According to an embodiment of the present invention, in one aspect, a guard 1 is provided, the guard 1 having a length direction, a width direction and a height direction, and the guard 1 extending in the length direction.

[0041] The edge protector 1 includes a substrate 101 and a hot melt adhesive layer 102. The substrate 101 includes a bottom wall 1011 and a side wall 1012. The bottom wall 1011 is used to support the backlight surface of the laminate 2 in the height direction. The side wall 1012 is connected to one end of the bottom wall 1011 in the width direction and is used to abut against the side of the laminate 2. The hot melt adhesive layer 102 is located on the same side of the bottom wall 1011 in the height direction as the side wall 1012 and covers the surface of the bottom wall 1011.

[0042] The edge protector 1 can form a photovoltaic frame, thereby protecting the laminate 2 and reducing the risk of the laminate 2 being broken by impact.

[0043] The edge protector 1 uses hot melt adhesive as the bonding material to the laminate 2, and the hot melt adhesive is prefabricated together with the substrate 101 in the form of a hot melt adhesive layer 102 (i.e., in a cured state). During the assembly of the photovoltaic module, the raw materials of the laminate 2 are stacked on the edge protector 1, and the edge protector 1 and the laminate 2 are laminated together. During the lamination process, the hot melt adhesive layer 102 is heated and melted to generate flowing hot melt adhesive, which fills the gap between the bottom wall 1011 and the laminate 2 and the gap between the side wall 1012 and the laminate 2 under extrusion. After lamination is completed, the hot melt adhesive cools and solidifies, thereby bonding the edge protector 1 and the laminate 2 while forming the laminate 2. This eliminates the need for applying adhesive to the edge protector 1 and assembling the edge protector 1 after lamination, which helps to reduce the assembly cost of the photovoltaic module.

[0044] Furthermore, the hot melt adhesive layer 102 can remain stable for a long time in the cured state, making the edge protector 1 with the hot melt adhesive layer 102 suitable for bulk packaging, storage, and integrated shipment. It can be used at any time during assembly, avoiding on-site application of adhesive before assembly, and further reducing the assembly cost of photovoltaic modules.

[0045] In some embodiments, the bottom wall 1011 is provided with an adhesive reservoir, and the hot melt adhesive layer 102 is at least partially located within the reservoir. The hot melt adhesive layer 102 filling the adhesive reservoir helps to increase the volume of the hot melt adhesive layer 102, thereby enabling it to more fully fill the gap between the substrate 101 and the laminate 2 during lamination, so that the edge protector 1 is more tightly and reliably bonded to the laminate 2.

[0046] In some embodiments, the sidewall 1012 is provided with an overflow groove 1013. During the lamination process, the molten hot melt adhesive layer 102 overflows to all sides under the pressure of the laminate 2, and a portion of the hot melt adhesive flows between the sidewall 1012 and the side surface of the laminate 2, causing the sidewall 1012 and the side surface of the laminate 2 to bond together. The overflow groove 1013 can store hot melt adhesive, thereby increasing the volume of hot melt adhesive between the sidewall 1012 and the laminate 2 and improving the tightness of the bond.

[0047] In some embodiments, the depth of the adhesive reservoir gradually decreases from the end near the sidewall 1012 to the end away from the sidewall 1012 in the width direction. By employing an inclined adhesive reservoir, more molten hot melt adhesive can be guided to flow towards the sidewall 1012, thereby increasing the flow between the sidewall 1012 and the side surface of the laminate 2, improving the tightness of the bond between the sidewall 1012 and the side surface of the laminate 2. Simultaneously, this also reduces the risk of hot melt adhesive overflowing from the end away from the sidewall 1012 onto the bottom wall 1011 during lamination, helping to reduce the cleaning costs of photovoltaic modules.

[0048] The substrate 101 can be made of either a metallic or non-metallic material, as long as it can protect the laminate 2 and meet the weather resistance requirements of the operating environment. This invention does not impose any restrictions on this. For example, the metallic material can be aluminum alloy, and the non-metallic material can be any one of nylon (e.g., PA66), polyphenylene ether, polyethylene, polypropylene, or polyvinyl chloride (including modified polyvinyl chloride).

[0049] In some embodiments, the hot melt adhesive layer 102 is made of ethylene-vinyl acetate copolymer (EVA). EVA material has good weather resistance and adhesion, can reliably connect the substrate 101 and the laminate 2, and can withstand harsh outdoor environments, thus improving the service life of the edge protector 1.

[0050] Secondly, this utility model provides a photovoltaic module, including a photovoltaic frame and a laminate 2. The photovoltaic frame includes a protective edge 1 provided by this utility model. Multiple protective edges 1 are arranged to form an installation space. The laminate 2 is disposed on the photovoltaic frame. The photovoltaic frame and the laminate 2 are integrally laminated.

[0051] For example, refer to Figure 3 , Figure 4 and Figure 5 The photovoltaic frame includes two sets of protective edges 1 in pairs, with each protective edge 1 connected end to end to form a square installation space. In other embodiments not shown, the photovoltaic frame may also be in other shapes, which are not limited by this invention.

[0052] The photovoltaic module includes the edge protector 1 provided by this utility model, and therefore has the beneficial effects brought by the edge protector 1, which will not be described in detail here.

[0053] In some embodiments, the light-facing surface of the laminate 2 is higher than or flush with the sidewall 1012. Having the light-facing surface higher or flush with the sidewall 1012 prevents water and dust accumulation between the sidewall 1012 and the laminate 2, reducing interference with the power generation capacity of the laminate 2.

[0054] In some embodiments, the photovoltaic frame further includes corner protectors 3, which are connected between two adjacent edge protectors 1. Using corner protectors 3 to connect the edge protectors 1 allows for pre-positioning of the edge protectors 1 before lamination, improving the positional accuracy of the edge protectors 1. Furthermore, the corner protectors 3 can enhance the strength of the photovoltaic frame at the corners, improving its impact resistance.

[0055] In addition, in some related technologies, a 45° bevel (i.e., chamfer) needs to be cut at the end of the frame during assembly so that two adjacent frames can abut against each other. The chamfering step also increases the cost of photovoltaic module assembly. By using corner protectors 3 for positioning and connection, the edge protectors 1 do not need to be chamfered, thereby further reducing the assembly cost of photovoltaic modules.

[0056] The corner protector 3 can be pressed together with the edge protector 1 during lamination, or it can be placed between two adjacent edge protectors 1 after lamination and bonded to the edge protector 1 with glue. This utility model does not limit this.

[0057] Reference Figure 6 Thirdly, this utility model also provides an edge protection manufacturing device for manufacturing the edge protection 1 provided by this utility model, including an extruder 401, a first shaping machine 402, a glue coating machine 403, and a second shaping machine 404. The extruder 401 is used to extrude and shape the substrate 101. The first shaping machine 402 is located downstream of the extruder 401 and is used to cool and shape the substrate 101. The glue coating machine 403 is located downstream of the first shaping machine 402 and is used to coat the bottom wall 1011 with a hot melt adhesive layer 102. The second shaping machine 404 is located downstream of the glue coating machine 403 and is used to cool and cure the hot melt adhesive layer 102.

[0058] Taking a non-metallic material substrate 101 as an example, the edge protection device can produce edge protection 1 according to the following steps:

[0059] The plastic particles required for producing the substrate 101 are precisely fed into the extruder 401 through the feeding port. The heating system inside the extruder 401 heats and melts the plastic particles. Then, these melted plastic particles are extruded into the substrate 101 according to the predetermined shape and size using the custom mold built into the extruder 401.

[0060] When the extruded substrate 101 is processed by the first shaping machine 402, it will be pre-shaped by cooling to ensure its shape stability. In order to meet the needs of subsequent production processes, the pre-shaped substrate 101 needs to be kept at a certain temperature to facilitate subsequent processing.

[0061] After the initial shaping, the substrate 101 will enter the coating machine 403 for the next step of processing. In the coating machine 403, plastic particles for producing hot melt adhesive are fed in through the feeding port. The plastic particles are melted by the internal heating system and then evenly coated onto the surface of the substrate 101.

[0062] The substrate 101 with hot melt adhesive applied will enter the first setting machine 402. Through cooling, the hot melt adhesive will be rapidly cured on the surface of the substrate 101 to form a thin and uniform hot melt adhesive layer 102.

[0063] The edge-protecting device is used to produce the edge-protecting 1 provided by this utility model, and therefore has the beneficial effects brought by the edge-protecting 1, which will not be elaborated here.

[0064] In some embodiments, the first shaping machine 402 includes a cooling fan, and the first shaping machine 402 cools down by air cooling (blowing air onto the surface of the substrate 101) to avoid the temperature of the substrate 101 being too low. In some embodiments, the second shaping machine 404 includes a cooling water pipe, and the first shaping machine 402 cools down by water cooling (spraying cooling water onto the surface of the substrate 101 away from the hot melt adhesive layer 102) to quickly cool the hot melt adhesive layer 102 and the substrate 101, so that the edge protector 1 is bent and shaped.

[0065] In some embodiments, the edge protection manufacturing apparatus further includes a cutting machine 405, which is located downstream of the second shaping machine 404. The cutting machine 405 cuts the manufactured edge protection 1 to a suitable length so as to assemble it into a photovoltaic frame.

[0066] Although embodiments of the present invention have been described in conjunction with the accompanying drawings, those skilled in the art can make various modifications and variations without departing from the spirit and scope of the present invention, and such modifications and variations all fall within the scope defined by the appended claims.

Claims

1. A protective edge, characterized in that The edge protector (1) has a length direction, a width direction, and a height direction, and the edge protector (1) extends in the length direction. The edge protector (1) includes: The substrate (101) includes a bottom wall (1011) and a side wall (1012). The bottom wall (1011) is used to support the back surface of the laminate (2) in the height direction, and the side wall (1012) is connected to one end of the bottom wall (1011) in the width direction and is used to abut against the side of the laminate (2). A hot melt adhesive layer (102) is located on the same side of the bottom wall (1011) in the height direction as the side wall (1012) and covers the surface of the bottom wall (1011).

2. The strip of claim 1, wherein The bottom wall (1011) is provided with an adhesive storage tank, and the hot melt adhesive layer (102) is at least partially located in the adhesive tank.

3. The strip of claim 2, wherein The side wall (1012) is provided with an overflow groove (1013).

4. The strip of claim 3, wherein In the width direction, the depth of the glue storage tank gradually decreases from the end near the sidewall (1012) to the end away from the sidewall (1012).

5. The strip of claim 1 wherein, The substrate (101) is made of a metallic material or a non-metallic material. The metallic material includes aluminum alloy, and the non-metallic material includes any one of nylon, polyphenylene ether, polyethylene, polypropylene, and polyvinyl chloride.

6. The strip of claim 1 wherein, The hot melt adhesive layer (102) is made of ethylene-vinyl acetate copolymer.

7. A photovoltaic module, characterized by include: A photovoltaic frame, including the edge guard (1) as described in any one of claims 1 to 6, wherein a plurality of the edge guards (1) enclose an installation space; A laminate (2) is disposed on the photovoltaic frame, and the photovoltaic frame and the laminate (2) are integrally laminated.

8. The photovoltaic module according to claim 7, characterized in that, The light-facing surface of the laminate (2) is higher than or flush with the sidewall (1012).

9. The photovoltaic module of claim 7, wherein, The photovoltaic frame also includes corner protectors (3), which are connected between two adjacent edge protectors (1).

10. A device for making a border, characterized in that For making the edge guard (1) according to any one of claims 1 to 6, comprising: An extruder (401) is used for extruding the substrate (101); A first shaping machine (402), located downstream of the extruder (401), is used to cool and shape the substrate (101); A coating machine (403), located downstream of the first setting machine (402), is used to coat the bottom wall (1011) with a hot melt adhesive layer (102); The second setting machine (404), located downstream of the glue spreading machine (403), is used to cool and cure the hot melt adhesive layer (102).

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