Solar module frame profile and method for producing the solar module frame profile

Abstract

The invention relates to a solar module frame profile for framing a solar module laminate (L) with a solar module laminate front side and a solar module laminate back side, wherein the solar module frame profile has a frame groove which is formed from: - a front side leg (1) for engaging over the solar module laminate front side along a solar module laminate edge, wherein the front side leg (1) has a front side end section (11), - a rear side leg (3) for engaging over the solar module laminate rear side along the solar module laminate edge, wherein the rear side leg (1) has a rear side end section (11), and - a frame groove web (2) which spaces the front side leg (1) and the rear side leg (3) apart from one another, and from which the front side leg (1) and the rear side leg (3) extend laterally along an opening direction (O) to form the frame groove, wherein the rear side leg end section (31) forms a support area projecting beyond the rear side adhesive plane in the direction of the front side end section (11) and / or a bevelled entry ramp section for introducing the solar module laminate in the direction of the frame groove web (2) of the solar module frame profile over the solar module laminate rear side, wherein the bevelled entry ramp projects beyond the rear side adhesive plane at least in sections and wherein the solar module frame profile consists of a bent metal strip.Furthermore, the invention relates to a method for producing the solar module frame profile, wherein the solar module frame profile is produced by bending the metal strip.

Description

[0001] The invention relates to a solar module frame profile and a method for producing the solar module frame profile. In particular, the invention relates to a solar module frame profile for framing a solar module laminate having a solar module laminate front side and a solar module laminate back side, and to a method for producing such a solar module frame profile.

[0002] Solar module laminates are often constructed with a carrier surface in the form of a glass pane, on which solar cells are arranged in so-called strings, electrically interconnected. These cells are laminated between the glass pane and a permanently weather-resistant plastic film and embedding polymers. The glass pane forms the front of the solar module laminate, and the weather-resistant plastic film forms the back of the solar module laminate. Instead of the weather-resistant plastic film, the back of the solar module laminate can also be formed by another glass pane in another variant. A solar module laminate manufactured in one or the other variant can be bonded to a solar module frame profile to increase its stability and rigidity and / or to create a mechanical mounting option via the frame profiles.The laminate layer structure of glass pane(s), solar cell strings, embedding polymers and possibly weather-resistant plastic film, which has not yet been combined with solar module frame profiles, is referred to in this invention as the solar module laminate.

[0003] A solar module frame profile for solar module laminates is known from DE 10 2016 102 335 A1. The solar module frame profile described therein has a frame groove formed from: - a front side leg for overlapping the solar module laminate front side along a solar module laminate edge, - a backside leg for overlapping the solar module laminate backside along the solar module laminate edge and - a frame groove web that spaces the front side leg and the rear side leg apart from one another, and from which the front side leg and the rear side leg extend laterally along an opening direction, forming the frame groove. As a result, the frame groove, which represents a laminate receiving area of the solar module frame profile, has a U-shaped configuration. Viewed in a cross-section oriented perpendicular to the plane of the solar module laminate and along the opening direction, the front side leg has a front side leg end section spaced from the frame groove web and a front side leg extension section arranged between the frame groove web and the front side leg end section, which defines a front side bonding plane for bonding the solar module frame profile to the solar module laminate front side.The front-side leg end section protrudes from the front-side bonding plane by an adhesive dimension in the direction of the rear-side leg. At least one adhesive cavity for receiving adhesive is formed in the front-side leg beyond the adhesive dimension. Alternatively or additionally, at least one adhesive cavity for receiving adhesive is formed in the front-side leg end section. The rear-side leg extends directly along the frame groove web with an obtuse opening angle in the range of 95 to 120 degrees.

[0004] However, the solar module frame profile described in DE 10 2016 102 335 A1 has the following disadvantages. A sharp edge on the frame groove can lead to an increased risk of glass breakage in the solar module laminate if module clamps are mounted on the front of the solar module frame profile. Furthermore, only uneven wetting and thickness of the adhesive or sealant on the front and back of the solar module laminate is achieved due to uncontrolled positioning of the solar module laminate in the frame groove. Furthermore, the adhesive or sealant on the front of the solar module laminate can leak out uncontrollably. Furthermore, increased adjustment effort is required in a framing station for the frame of the solar module laminate in order to insert the solar module laminate evenly into the frame groove.

[0005] The present invention is therefore based on the object of providing a solar module frame profile with reduced assembly risks and / or process risks and a method for producing such a solar module frame profile.

[0006] This object is achieved by a solar module frame profile having the features of claim 1 and by a method having the features of claim 7. Preferred embodiments emerge from the subclaims explained below.

[0007] According to the invention, it is provided that the rear side leg end section forms a support area projecting beyond the rear side adhesive plane in the direction of the front side end section and / or a beveled entry ramp section for introducing the solar module laminate in the direction of the frame groove web of the solar module frame profile over the solar module laminate rear side, wherein the beveled entry ramp projects at least partially beyond the rear side adhesive plane and that the solar module frame profile consists of a bent metal strip.

[0008] The frame groove, in the form of the U-shaped laminate receiving area of the solar module frame profile, reduces assembly and / or process risks: The laminate receiving area of the solar module frame profile is improved by the support area and / or the beveled entry ramp section. The risk of glass breakage is reduced when inserting the solar module laminate over the rear side leg. The support area and / or the beveled entry ramp section can have different lengths and can thus be adapted to the solar module laminates to be framed.

[0009] Furthermore, the support area and / or the beveled entry ramp section provide cavities for the adhesive or sealant, such as silicone, above and below the solar module laminate. This ensures uniform wetting of the adhesive or sealant on the front and back of the solar module laminate.

[0010] This design of the frame groove further reduces the risk of glass breakage when using solar module laminates with a front and / or back made of glass and compared to the use of module clamps such as widely used extruded aluminum clamps on the solar module frame profile.

[0011] In summary, the following advantages can be achieved: The optimized frame groove design reduces the risk of glass breakage when used with glass-containing solar module laminates by increasing the contact area between the frame groove and the solar module laminate. The optimized frame groove design leads to improved alignment of the solar module laminate in the frame groove. By optimizing the insertion area between the frame groove and the solar module laminate, glass-to-glass solar module laminates, i.e. solar module laminates with a glass front and a glass back, can also be joined in a controlled manner using the frame groove and the frame groove reduces the setup effort in the framing station. A controlled and uniform minimum adhesive or sealant thickness on the front and back of the solar module laminate is achieved.

[0012] The fact that the solar module frame profile is bent from a metal strip further supports the advantages described above. Surprisingly, it was discovered that it is possible to bend the complex solar module frame profile described above in one piece from a single metal strip. The metal strip can be bent into the solar module frame profile according to the invention without bulging, tearing, or wrinkling, particularly in its bent sections. This simplifies the production of the solar module frame profile and reduces the resulting costs because bending metal strips is generally more cost-effective than producing extruded frame profiles, which is usually done with comparatively expensive and very energy-intensive aluminum materials.

[0013] The thickness of the solar module laminate typically tapers toward the edge because the laminated solar cells connected to strings do not extend to the edge of the solar module laminate. Particularly when the front of the solar module laminate is made of glass and the back of the solar module laminate is made of a weather-resistant plastic film, the arrangement of the solar cells in the solar module laminate, which does not extend to the edge, results in the front being essentially flat, while the laminate thickness of the back of the solar module laminate increases slightly from the edge areas toward the center of the solar module laminate.When inserting the solar module laminate into the solar module frame profile, the front side of the solar module laminate, with its planar surface, is oriented essentially perpendicular to the frame groove web, while the rear side of the solar module laminate forms a surface in the edge area that runs at a non-right angle to the frame groove web. The beveled entry ramp section of the rear side leg end section is preferably adapted to this angle.

[0014] The solar module frame profile preferably has an entry ramp area for the solar module laminate, which is essentially formed by the rear leg end portion, which fulfills the function of an entry ramp for the solar module laminate during insertion. The solar module frame profile preferably has a solar module laminate alignment opening, which is essentially formed by the front leg end portion and the rear leg end portion, which fulfills the function of aligning the solar module laminate during insertion.

[0015] The front-side leg extension section and / or the rear-side leg extension section are preferably each formed such that they each form a cavity in spatial relationship to the framed solar module laminate, each receiving an adhesive for bonding the solar module laminate to them. As a result, the solar module frame profile has two bonding regions that are formed substantially along the front-side leg extension section and the rear-side leg extension section, which, using an adhesive, fulfill the function of bonding the solar module laminate. Preferably, the rear-side leg end section protrudes in the direction of the front-side leg from the rear-side bonding plane by a further bonding dimension, which may be the same as or different from the bonding dimension.This prevents or at least reduces unwanted adhesive leakage from the frame groove on the front and back of the solar module laminate.

[0016] In a preferred embodiment, the metal strip is formed as a steel strip. This further reduces the costs of manufacturing the solar module frame profile. In addition, suitable steel materials exhibit sufficient flexural strength and formability.

[0017] Preferably, the steel strip has a uniform material thickness that varies by less than 5%. Preferably, the steel strip has a uniform material thickness that varies by less than 3%. As a result, the solar module frame profile has uniform stability in its different sections along its extension and can be bent from steel sheets that have correspondingly constant sheet thicknesses.

[0018] In a preferred embodiment, the front-side leg end section has a profile edge that, when the solar module laminate is inserted, is oriented parallel to the solar module laminate front side. When the solar module laminate is clamped to the front-side leg, the risk of breakage is further reduced by the profile edge being parallel to the solar module laminate front side.

[0019] The front-side extension section is preferably formed substantially perpendicularly in the front-side bonding plane or perpendicular to the frame groove web and is therefore also adapted to the solar module laminate front side, which is substantially planar and is also aligned perpendicularly to the frame groove web when the solar module laminate is inserted into the solar module frame profile. As a result, the solar module frame profile is adapted to the front-side dimensions of the solar module laminate, so that during bonding, preferably uniform adhesive wetting can be achieved between the solar module laminate front side and the solar module frame profile. Furthermore, this reduces the amount of adhesive required to fix the solar module laminate in the frame profile.

[0020] The rear-side extension section can be formed substantially perpendicular to the rear-side bonding plane or perpendicular to the frame groove web. This forms the aforementioned cavity, since the rear-side leg end section forms the support area projecting beyond the rear-side bonding plane in the direction of the front-side end section and / or the beveled entry ramp section, which at least partially projects beyond the rear-side bonding plane.

[0021] The solar module frame profile preferably further comprises a fixing section designed to fix the solar module frame profile in a mounting position on a support element, and to connect the rear leg end section to the fixing section via a connecting section, wherein the entire solar module frame profile is formed in one piece. This means that the solar module frame profile, which has the frame groove, the fixing section, and the connecting section, is bent from a single metal strip. The fixing section is preferably designed to be fixed to the support element by means of a releasable fastening means in the form of a screw. The support element forms or is part of a more complex mechanical support structure that serves for the permanent installation of the solar modules.

[0022] In a further preferred embodiment, the connecting portion extends from an end of the rear side leg opposite the rear side leg extension portion. This allows the solar module frame profile to be easily manufactured from a metal strip by bending.

[0023] The invention further relates to a method for producing a solar module frame profile according to one or more of the embodiments described above, in which the solar module frame profile is produced by bending the metal strip.

[0024] Bending is a group of manufacturing processes that fall under the category of forming. A wide variety of bending processes can be used, including air bending, die bending, roll bending, three-point bending, folding, closing, swivel bending, round bending, rotary bending, press bending, and compression bending.

[0025] The advantages described in connection with the different structural designs of the solar module frame profiles apply accordingly to the process and the immediate process product in the form of the bent frame profile.

[0026] In a preferred embodiment, the metal strip has a uniform material thickness before bending. Depending on the metal material used and the bending process, the material thickness in bent areas may be slightly thinner or thicker after bending than in unbent areas, which retain the original material thickness.

[0027] Further properties and advantages of the solar module frame profile according to the invention are explained in more detail in the context of the preferred embodiments described below. It shows schematically and not to scale: Fig. 1 a cross-sectional view of a solar module frame profile according to a first embodiment; Fig. 2 a cross-sectional view of a solar module frame profile according to a second embodiment; Fig. 3 to 5 process steps when inserting a solar module laminate into the Fig. 1 solar module frame profile shown; Fig. 6 a cross-sectional view of the Fig. 2 shown solar module frame profile with an inserted solar module laminate and Fig. 7 an enlarged detailed view of the Fig. 5 shown solar module frame profile with inserted solar module laminate.

[0028] Fig. 1 shows a cross-sectional view of a solar module frame profile according to a first embodiment. The solar module frame profile is formed to frame a solar module laminate (not shown) with a solar module laminate front side (not shown) and a solar module laminate back side (not shown). The solar module frame profile has a frame groove formed from a front side leg 1 for engaging over the solar module laminate front side along a solar module laminate edge, a back side leg 3 for engaging over the solar module laminate back side along the solar module laminate edge, and a frame groove web 2 that spaces the front side leg 1 and the back side leg 3 apart and from which the front side leg 1 and the back side leg 3 extend laterally along an opening direction O, forming the frame groove.

[0029] Viewed in a cross-section perpendicular to the plane of the solar module laminate and oriented along the opening direction O, the front side leg 1 has a front side leg end section 11 spaced from the frame groove web 2 and a front side leg extension section 12 arranged between the frame groove web 2 and the front side leg end section 11, which defines a front side bonding plane V for bonding the solar module frame profile to the solar module laminate front side. The front side leg end section 11 protrudes from the front side bonding plane V by an adhesive dimension K in the direction of the rear side leg 3 and thereby forms a cavity 6 for receiving adhesive.

[0030] The rear side leg 3, viewed in a cross-section perpendicular to the plane of the solar module laminate and oriented along the opening direction O, has a rear side leg end section 31 spaced from the frame groove web 2 and a rear side leg extension section 32 arranged between the frame groove web 2 and the rear side leg end section 31, which spans a rear side adhesive plane R for bonding the solar module frame profile to the solar module laminate rear side. The rear side leg end section 31 forms a support area projecting beyond the rear side adhesive plane R in the direction of the front side end section 11 and / or a beveled entry ramp section for inserting the solar module laminate in the direction of the frame groove web 2 of the solar module frame profile over the solar module laminate rear side. The bevelled entry ramp protrudes at least in sections beyond the back adhesive plane R.The rear side leg end section 31 protrudes in the direction of the front side leg 1 from the rear side adhesive plane R by a further adhesive dimension K1, which can be the same as or different from the adhesive dimension K. In this case, a further cavity 6 is formed for receiving adhesive.

[0031] The front leg end portion 11 and the rear leg end portion 31 together form a solar module laminate alignment opening for the solar module laminate to be framed, which is designed to fix the solar module laminate in its framed final position.

[0032] In addition to the frame groove described above, the solar module frame profile further comprises a fixing section 5, which is designed to be able to fix the solar module frame profile in an assembly position on a support element (not shown), and to connect the rear side leg end section 31 to the fixing section 5 via a connecting section 4. The connecting section 4 extends away from an end of the rear side leg 31 opposite the rear side leg extension section 32.

[0033] The Fig. The solar module frame profile shown in Figure 1 is formed in one piece. It consists of a single-piece, bent metal strip. In particular, the solar module frame profile consists of a steel strip that has a uniform material thickness along its length, which varies by less than 5%, preferably by less than 3%.

[0034] The solar module frame profile is manufactured by bending the metal strip. The metal strip has a uniform material thickness before bending.

[0035] Fig. 2 shows a cross-sectional view of a solar module frame profile according to a second embodiment. Fig. The solar module frame profile shown in Figure 2 corresponds to the one shown in Fig. 1, with the difference that the rear leg end section 31 has a smaller extension length in the opening direction O. For the sake of clarity, the adhesive dimension and the further adhesive dimension are not shown.

[0036] Fig. 3 to 5 show process steps when inserting a solar module laminate into the Fig. 1. For clarity, the bonding dimension and the further bonding dimension are not shown in the figures. A solar module laminate L with a solar module laminate front side and a solar module laminate back side is produced with the Fig. 1 shown solar module frame profile. In Fig. 3 shows how the solar module laminate L is inserted into the frame profile in the direction of the thick arrow, i.e. in the direction opposite to the opening direction O. In Fig. 4 shows that the solar module laminate is further inserted into the frame profile along the entry ramp section of the rear leg end section 31. In Fig. 5 shows the solar module laminate L framed by the solar module frame profile, which is now inserted into the U-shaped frame groove. The front-side leg extension section 12 and the rear-side leg extension section 32 are each formed such that they each form a cavity 6 in spatial relation to the solar module laminate L, into which an adhesive (not shown) can enter when the solar module laminate L is bonded to the frame profile.

[0037] Fig. 6 shows a cross-sectional view of the Fig. 2 shown solar module frame profile with an inserted solar module laminate. The Fig. 6 solar module frame profile corresponds to the one shown in Fig. 5, with the difference that the rear leg end section 31 has a smaller extension length in the opening direction O. In particular, its entry ramp section has a smaller extension length viewed in the opening direction O.

[0038] Fig. 7 shows an enlarged detailed view of the Fig. 5 with the solar module laminate inserted. The front side leg end section 11 has a profile edge 111 which, when the solar module laminate L is inserted, is oriented substantially parallel to the solar module laminate front side.

[0039] Furthermore, Fig.7 illustrates various functionalities of the solar module frame profile. The solar module frame profile has a solar module laminate alignment opening A, as indicated by the dashed line, which is essentially formed by the front leg end portion 11 and at least a part of the rear leg end portion 31. The solar module laminate alignment opening A provides the functionality of mechanically aligning the solar module laminate L during insertion into the frame profile. Furthermore, the solar module frame profile has an entry ramp area E for the solar module laminate L, as illustrated by the area framed by a dotted line. The entry ramp area E, which is essentially formed by the rear leg end portion 31, provides the functionality of a sliding ramp for the solar module laminate L during insertion into the frame profile.This further supports the alignment of the solar module laminate L during insertion into the frame groove. Furthermore, the solar module frame profile has two adhesive areas KB, as illustrated by the coarsely dashed line. The two adhesive areas KB are essentially formed by the front leg extension section 12 and the rear leg extension section 32 and, when using an adhesive for framing the solar module laminate L, ensure the bonding of the solar module laminate L to the frame groove. List of reference symbols: A Solar module laminate alignment opening E Entry ramp area for solar module laminate K Adhesive dimension K1 additional adhesive dimension KB adhesive area L Solar module laminate O Opening direction R Back adhesive layer V Front adhesive layer 1 front leg 11 Front leg end section 111 Profile edge 12 Front leg extension section 2 frame groove web 3 back legs 31 Rear leg end section 32 Rear leg extension section 4 connecting section 5 Fixing section 6 Cavity QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] DE 10 2016 102 335 A1 [0003, 0004]

Claims

[1] Solar module frame profile for framing a solar module laminate (L) with a solar module laminate front side and a solar module laminate back side, wherein the solar module frame profile has a frame groove formed from: - a front side leg (1) for engaging over the solar module laminate front side along a solar module laminate edge, - a rear side leg (3) for engaging over the solar module laminate rear side along the solar module laminate edge and - a frame groove web (2) which spaced the front side leg (1) and the rear side leg (3) apart from each other, and from which the front side leg (1) and the rear side leg (3) extend laterally along an opening direction (O), forming the frame groove, wherein, viewed in a cross-section perpendicular to the plane of the solar module laminate (L) and oriented along the opening direction (O), the front side leg (1) has a front side leg end section (11) spaced from the frame groove web (2) and a front side leg extension section (12) arranged between the frame groove web (2) and the front side leg end section (11), which extends a front side bonding plane (V) for bonding the solar module frame profile to the solar module laminate front side, wherein the front side leg end section (11) protrudes from the front side bonding plane (V) by an adhesive dimension (K) in the direction of the rear side leg (3), wherein, viewed in a cross-section perpendicular to the plane of the solar module laminate (L) and oriented along the opening direction (O),the rear side leg (3) has a rear side leg end section (31) spaced from the frame groove web (2) and a rear side leg extension section (32) arranged between the frame groove web (2) and the rear side leg end section (31), which spans a rear side adhesive plane (R) for bonding the solar module frame profile to the solar module laminate rear side, , characterized by that the rear side leg end section (31) forms a support area projecting in the direction of the front side end section (11) beyond the rear side adhesive plane (R) and / or a bevelled entry ramp section for introducing the solar module laminate in the direction of the frame groove web (2) of the solar module frame profile over the solar module laminate rear side, wherein the bevelled entry ramp projects at least in sections beyond the rear side adhesive plane (R) and that the solar module frame profile consists of a bent metal strip. [2] Solar module frame profile according to claim 1, characterized by that the metal band is designed as a steel band. [3] Solar module frame profile according to claim 1, characterized by that the steel strip has a uniform material thickness which varies by less than 5%, preferably by less than 3%. [4] Solar module frame profile according to one of claims 1 to 3, characterized by that the front side leg end section (11) has a profile edge (111) which is oriented parallel to the solar module laminate front side when the solar module laminate (L) is inserted. [5] Solar module frame profile according to one of the preceding claims, characterized bya fixing section (5) which is designed to fix the solar module frame profile in a mounting position on a support element, and to connect the rear leg end section (31) to the fixing section (5) via a connecting section (4), wherein the entire solar module frame profile is formed in one piece. [6] Solar module frame profile according to claim 5, characterized by that the connecting portion (4) extends away from an end of the rear side leg (31) opposite the rear side leg extension portion (32). [7] Method for producing a solar module frame profile according to one of the preceding claims, characterized by that the solar module frame profile is manufactured by bending the metal strip. [8] Method according to claim 7, characterized by that the metal strip has a uniform material thickness before bending.

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