Lightweight Frame Photovoltaic Module and Method for Manufacturing the Same

Abstract

The present invention relates to a lightweight frame solar power generation module and a method for manufacturing the same. The lightweight frame solar power generation module includes a module body (2) and an L-shaped frame (1), and the L-shaped frame (1) and the module body (2) are adhered by a sealing material (4) flowing out from the module body (2). The manufacturing method includes assembling the L-shaped frame (1) to a laminated member before laminating the module to obtain a member to be laminated, and then laminating the member to be laminated to complete the sealing of the module and the adhesion between the L-shaped frame (1) and the module body (2). Since the L-shaped frame (1) is lightweight while protecting the module side, it can meet the requirement of weight reduction of the module. In addition, the L-shaped frame (1) does not affect the lamination of the module, and the frame (1) can be adhered by the sealing material (4) flowing out from the module body (2) during lamination, so the use of a silicon sealant and equipment investment are unnecessary, and the overall cost can be significantly reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of photovoltaic modules, and particularly to a lightweight frame photovoltaic module and a method for manufacturing the same.

Background Art

[0002] With the development of photovoltaic power generation technology, the cost of its modules has been gradually decreasing. However, due to the constraints of aluminum materials, the cost of its frame has not decreased much. As a result, the proportion of the frame cost in the total cost of the module has increased. In addition, since conventional frames are heavy, current lightweight modules adopt a frameless design in order to pursue lightness. However, in actual use, there is a lack of protection for the side surfaces of the glass modules, and the module may be discarded due to the rupture of the ends of the glass modules.

[0003] Regarding the conventional module frame, the frame is attached after the module is laminated, and the module frame and the module body are adhered by injecting silicone sealant.

[0004] The conventional module frame generally includes an upper part of the frame (also referred to as the A surface), a side part of the frame (also referred to as the B surface), and a lower part of the frame (also referred to as the C surface), and covers the edge of the light-receiving surface, the side surface, and the edge of the back surface of the module body, respectively. The thickness of the A surface of the module frame is generally 2 mm, and dust and dirt are likely to accumulate when used outdoors for a long time, which may affect the power generation amount of the module.

[0005] Through prior art research, it was found that in prior arts such as Chinese document CN214256207U and Chinese document CN217949570U, there is a module frame excluding surface A to solve the problem of dust accumulation. However, in all of the above prior arts, the frame is attached after laminating the module, and the module frame and the module body are adhered by injecting a silicone sealant.

Summary of the Invention

[0006] The technical problem to be solved by the present invention is how to further simplify the attachment of the frame and reduce costs.

[0007] The technical solution adopted by the present invention to solve the above technical problem is a lightweight frame solar power generation module. The lightweight frame solar power generation module includes a module body and a frame located on the side of the module body. The frame is an L-shaped frame, and the L-shaped frame includes a frame lower part located on the back surface of the module body and a frame side part located on the side surface of the module body. The L-shaped frame and the module body are adhered by a sealing material flowing out from the module body.

[0008] Furthermore, between the frame side part and the side surface of the module body, and between the frame lower part and the back surface of the module body, there is a sealing material flowing out from the module body for adhering the frame and the module body.

[0009] Furthermore, the frame side part is flush with the light-receiving surface of the module body, or is formed lower than the light-receiving surface of the module body, and the height difference between the two is 0.5 mm or less.

[0010] Furthermore, the L-shaped frame is made of a metal material including aluminum, stainless steel, etc., or an organic material resistant to high temperatures by laminating epoxy resin, PC, PP, polyurethane, etc.

[0011] Furthermore, the L-shaped frame has a solid structure or a hollow structure, and the inner wall of the L-shaped frame is a plane or a non-plane having concave grooves and / or convex ribs.

[0012] Furthermore, the thickness of the side part of the frame is 0.1 mm to 5 mm, the thickness of the lower part of the frame is 0.1 mm to 3 mm, the width of the lower part of the frame is 1 mm to 20 mm, the length of the L-shaped frame is 10 mm to 3000 mm, the L-shaped frame is the same as the length of the side of the corresponding module body, or the L-shaped frame is a short frame shorter than the length of the side of the corresponding module body.

[0013] Furthermore, all or part of the sides of the module body employ an L-shaped frame.

[0014] Furthermore, the sealing material in the module body is an EVA adhesive, a POE adhesive, an EPE adhesive, a PVB adhesive, or a PEP adhesive, etc.

[0015] Furthermore, the frame is a long frame or an assembled frame composed of at least two long frames.

[0016] The manufacturing method of the lightweight frame solar power generation module described above is to assemble the L-shaped frame to the laminated member before laminating the module to obtain a member to be laminated, and then laminate the member to be laminated to complete the sealing of the module and the adhesion between the L-shaped frame and the module body.

[0017] Furthermore, the L-shaped frame is assembled to the laminated member by fixing a temporary fixing member.

[0018] Furthermore, specifically, (1) a module lamination step of laminating the structures of the respective layers of the module body to obtain a laminated member; (2) a frame attachment step of attaching an L-shaped frame to the side surface of the laminated member, temporarily fixing the L-shaped frame with a temporary fixing member to obtain a member to be laminated; (3) a module lamination step of laminating the member to be laminated, allowing the sealing material that has flowed out during lamination to enter the gap between the frame and the module body, and completing the sealing of the module and the adhesion between the L-shaped frame and the module body; and (4) a post-lamination processing step of performing subsequent production of the module and removing the temporary fixing member.

[0019] Furthermore, the temporary fixing member is an adhesive tape.

[0020] Furthermore, specifically, the adhesive tape is a high-temperature resistant adhesive tape that can withstand a temperature equal to or higher than the lamination temperature.

[0021] In addition to being assembled to the laminated member by fixing the temporary fixing member, the frame can be assembled to the laminated member by its own structure. For example, first, the L-shaped frames are integrally combined and fixed, and then the integrally combined and fixed L-shaped frames are placed over the laminated member to achieve the assembly of the L-shaped frame and the laminated member.

[0022] The beneficial effects of the present invention are as follows. Since the L-shaped frame protects the side of the module and is lightweight, it can meet the requirement for weight reduction of the module. In addition, the L-shaped frame has no A surface, avoiding the problem of dust accumulation at the front edge of the module outside, and contributing to an improvement in power generation. Also, since the L-shaped frame has no A surface and at the same time the sizes of the B surface and the C surface are significantly reduced compared to conventional frames, the cost of the frame is significantly reduced. Moreover, the L-shaped frame does not affect the lamination of the module, and since the frame can be adhered by the sealing material that has flowed out from the module body during lamination, the use of silicone sealant and equipment investment are not required, and the overall cost can be significantly reduced.

Brief Description of the Drawings

[0023] Hereinafter, the present invention will be further described with reference to the drawings and embodiments.

[0024]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Embodiments for Carrying Out the Invention

[0025] As shown in FIGS. 1 to 6, the lightweight frame solar power generation module includes a module body 2 and a frame 1 located on the side of the module body 2. The frame 1 is an L-shaped frame, and the L-shaped frame includes a frame lower part 1-2 located on the back surface of the module body 2 and a frame side part 1-1 located on the side surface of the module body 2. The L-shaped frame and the module body 2 are adhered by a sealing material 4 flowing out from the module body 2.

[0026] In the present specification, the laminated member is a general term for the structures of the respective layers of the module before lamination, and the module body is a general term for the structures of the respective layers of the module after lamination.

[0027] As shown in Fig. 4, there is a sealing material 4 flowing out from the module body 2 for bonding the frame 1 and the module body 2 between the side part 1-1 of the frame and the side surface of the module body 2, and between the lower part 1-2 of the frame and the back surface of the module body 2.

[0028] The sealing material 4 in the module body 2 is an EVA adhesive or a POE adhesive, but it can also be other sealing materials that can be used for sealing modules such as EPE adhesives, PVB adhesives, and PEP adhesives.

[0029] The side part 1-1 of the frame is flush with the light-receiving surface of the module body 2. Note that the side part 1-1 of the frame may be slightly lower than the light-receiving surface of the module body 2. The height difference between the two is 0.5 mm or less. Before lamination, the side part 1-1 of the frame is lower than the laminated member. The thickness of the side part 1-1 of the frame is 0.1 - 5 mm, the thickness of the lower part 1-2 of the frame is 0.1 - 3 mm, and the width of the lower part 1-2 of the frame is 1 - 20 mm.

[0030] The L-shaped frame is made of a metal material such as aluminum or stainless steel, or an organic material that can withstand high temperatures by lamination such as epoxy resin, PC, PP, or polyurethane.

[0031] As shown in Fig. 4, the L-shaped frame has a solid structure, and the inner wall of the L-shaped frame is a plane.

[0032] As shown in Figs. 2 and 3, the module body 2 includes a front panel 2-1, a sealing material layer 2-2, a cell sheet layer 2-3, a sealing material layer 2-2, and a back sheet 2-4.

[0033] In Figs. 1 - 6, L-shaped frames are attached to all four sides of the module body 2. The frame 1 is a long frame, and the widths of the lower parts 1-2 of the four frames 1 are the same. Note that the widths of the lower parts 1-2 may also be different.

[0034] In FIGS. 2, 5, and 6, the joints at the corners of each frame 1 are chamfered, thereby joining the frames 1 together. Also, the overlapping portion at the joint of one of the frames 1 can be cut off to join the frames 1 together.

[0035] The method for manufacturing a lightweight frame solar power generation module includes the following steps.

[0036] (1) Lamination of the module

[0037] The structures of the respective layers of the module body 2 were laminated from bottom to top in the order of the front panel 2-1, the encapsulant layer 2-2, the cell sheet layer 2-3, the encapsulant layer 2-2, and the back sheet 2-4 to obtain a laminated member.

[0038] (2) Attachment of the frame

[0039] An L-shaped frame was assembled to the side surface of the laminated member so as to be in close contact with the four sides and the back surface of the laminated member, and the L-shaped frame was temporarily fixed with a temporary fixing member to obtain a laminate target member as shown in FIG. 3. The temporary fixing member is a high-temperature resistant adhesive tape 3 that does not interfere with the subsequent lamination step while securely fixing the frame. The high-temperature resistant adhesive tape 3 covers from the side surface of the frame to the back surface and the light-receiving surface of the laminated member so as to securely temporarily fix the frame 1.

[0040] (3) Lamination of the module

[0041] The laminate target member was placed in a laminating apparatus and laminated normally, and the encapsulant 4 that flowed out during lamination was filled into the gap between the frame 1 and the module body 2 to bond the L-shaped frame and the module body 2.

[0042] (4) Post-lamination treatment

[0043] After removing the high-temperature resistant adhesive tape 3, subsequent manufacturing of the module was performed, and the subsequent manufacturing process is the same as that of a normal module.

[0044] In step (4), only when the excess sealant 4 flows out from the frame 1, it is necessary to remove the high-temperature resistant adhesive tape 3 and at the same time remove the excess sealant 4 that has flowed out from the frame 1. The removal of the high-temperature resistant adhesive tape 3 and the excess adhesive can be carried out in the subsequent manufacturing process of any module as long as it does not affect the subsequent manufacturing of the module.

[0045] Compared with the conventional frame, the L-shaped frame according to this embodiment has the upper part of the frame removed, the height and thickness of the side part 1-1 of the frame are significantly reduced, and the width of the lower part 1-2 of the frame is reduced. Therefore, the weight of the frame 1 can be significantly reduced, and the cost of the frame 1 can be significantly reduced. In addition, since the upper part of the frame is removed, the problem of dust accumulation in the module can be completely solved. Regarding the attachment of the frame 1, before lamination, the frame 1 is attached to the four sides of the module body 2 with the high-temperature resistant adhesive tape 3, and the attachment of the frame 1 is completed by the adhesive that has flowed out from the side to the outside during the lamination of the module. After the lamination is completed, the high-temperature resistant adhesive tape 3 and the excess adhesive that has flowed out can be removed. Therefore, the attachment process of the module frame can be simplified, the use of silicone sealant and equipment investment are not required, and the overall cost can be significantly reduced.

[0046] The above is only a preferred specific embodiment of the present invention, and the protection scope of the present invention is not limited thereto. Equivalent substitutions or modifications made by those skilled in the technical field of the present invention within the technical scope disclosed by the present invention based on the technical solution and inventive concept of the present invention are all included in the protection scope of the present invention.

[0047] For example, in order to realize the assembly of the L-shaped frame and the laminated member, it is not necessary to temporarily fix the frame 1 and the laminated member with a temporary fixing member. All the frames 1 can be welded, adhered or fastened with a fastener to form an assembled frame, and then the assembled frame can be covered on the laminated member. In this case, even without the temporary fixing member, the frame 1 and the laminated member will not separate during the lamination of the module, so the temporary fixing member can be omitted.

[0048] For example, the temporary fixing member is not limited to the high-temperature resistant adhesive tape 3. As long as the temporary fixing of the frame 1 and the laminated member can be performed before lamination and there is no obstacle to the lamination of the module, any temporary fixing member or fixing method may be used. When using other temporary fixing members, the steps of laminating the module and attaching the frame are not limited to this order and can be appropriately adjusted according to the temporary fixing method.

[0049] For example, as long as the adhesive strength can be ensured, there may be a sealing material 4 flowing out from the module body 2 only between the side part 1-1 of the frame and the side surface of the module body 2, or only between the lower part 1-2 of the frame and the back surface of the module body 2.

[0050] For example, the L-shaped frame has a hollow structure, and the inner wall of the L-shaped frame is a non-planar surface having concave grooves and / or convex ribs. The concave grooves and convex ribs can contribute to weight reduction and function as storage grooves for the adhesive.

[0051] For example, the module body 2 uses an L-shaped frame on some sides and does not use a frame on the remaining sides. Specifically, for example, the module body 2 uses an L-shaped frame on three sides and does not use a frame on the remaining one side.

[0052] For example, the lightweight frame of the lightweight frame solar power generation module according to the present invention is the L-shaped frame according to the present invention excluding the A surface. The technical solution of the present invention can also be used for conventional modules such as single-sided glass panels, double-sided glass panels, double-sided glass power generation panels, and flexible modules in addition to lightweight modules.

[0053] For example, in addition to the long frame, the frame 1 can be an assembled frame composed of at least two long frames 1. Specifically, any two frames 1 in FIG. 5 can be combined into an L-shaped assembled frame and assembled to other frames, or any three frames 1 in FIG. 5 can be combined into an assembled frame and assembled to other frames 1, or all four frames 1 in FIG. 5 can be combined into an assembled frame that matches the outer dimensions of the module.

[0054] For example, the length of the frame 1 of the module can be flexibly set according to the protection range of the module, and can be set to be long or short. Generally, the length of the frame 1 is 10 mm to 3000 mm. In FIGS. 2, 5, and 6, the frame 1 is the same as the length of the side of the corresponding module body 2. That is, the frame 1 in the longitudinal direction is equal in length to the long side of the module body 2, and the frame 1 in the short transverse direction is equal in length to the short side of the module body 2. However, as shown in FIGS. 7 and 8, when it is necessary to protect only the corners of the module, the frame 1 becomes a short frame and is formed as a corner guide at the corners of the module body 2.

Explanation of Signs

[0055] 1. Frame 1-1. Frame side part 1-2. Frame lower part 2. Module body 2-1. Front panel 2-2. Sealing material layer 2-3. Cell sheet layer 2-4. Back sheet 3. High-temperature resistant adhesive tape 4. Sealing material

Claims

1. It includes a module body (2) and a frame (1) located on the side of the module body (2). The frame (1) is an L-shaped frame, and the L-shaped frame includes a frame lower part (1-2) located on the back surface of the module body (2) and a frame side part (1-1) located on the side surface of the module body (2). The L-shaped frame and the module body (2) are adhered by a sealing material (4) flowing out from the module body (2). A lightweight frame solar power generation module, characterized in that.

2. Between the frame side part (1-1) and the side surface of the module body (2), and between the frame lower part (1-2) and the back surface of the module body (2), there is a sealing material (4) flowing out from the module body (2) for adhering the frame (1) and the module body (2). The lightweight frame solar power generation module according to claim 1, characterized in that.

3. The frame side part (1-1) is flush with the light-receiving surface of the module body (2), or is formed lower than the light-receiving surface of the module body (2), and the height difference between the two is 0.5 mm or less. The lightweight frame solar power generation module according to claim 1, characterized in that.

4. The L-shaped frame is made of a metal material including aluminum and stainless steel, or is made of an organic material resistant to high temperatures by laminating epoxy resin, PC, PP, polyurethane, etc. The lightweight frame solar power generation module according to claim 1, characterized in that.

5. The L-shaped frame has a solid structure or a hollow structure, and the inner wall of the L-shaped frame is a plane or a non-plane having concave grooves and / or convex ribs. The lightweight frame solar power generation module according to claim 1, characterized in that.

6. The thickness of the frame side part (1-1) is 0.1 mm to 5 mm, the thickness of the lower part of the frame (1-2) is 0.1 mm to 3 mm, and the width of the lower part of the frame (1-2) is 1 mm to 20 mm, the length of the L-shaped frame is 10 mm to 3000 mm, the L-shaped frame is the same as the length of the side of the corresponding module body (2), or the L-shaped frame is a short frame shorter than the length of the side of the corresponding module body (2) The lightweight frame solar power generation module according to claim 1, characterized in that.

7. The lightweight frame solar power generation module according to claim 1, characterized in that all or part of the side of the module body (2) employs an L-shaped frame.

8. The lightweight frame solar power generation module according to claim 1, characterized in that the encapsulant (4) in the module body (2) is an EVA adhesive, a POE adhesive, an EPE adhesive, a PVB adhesive or a PEP adhesive.

9. The lightweight frame solar power generation module according to claim 1, characterized in that the frame (1) is a long frame or an assembled frame composed of at least two long frames.

10. Before laminating the module, assemble the L-shaped frame to the laminating member to obtain a member to be laminated, and then laminate the member to be laminated to complete the sealing of the module and the adhesion between the L-shaped frame and the module body (2) The method for manufacturing a lightweight frame solar power generation module according to any one of claims 1 to 8, characterized in that.

11. The method for manufacturing a lightweight frame solar power generation module according to claim 10, characterized in that the L-shaped frame is assembled to the laminating member by fixing a temporary fixing member.

12. (1) A module lamination step of laminating each layer of the module body (2) to obtain a laminated member; (2) A frame attachment step of assembling an L-shaped frame to the side surface of the laminated member, temporarily fixing the L-shaped frame with a temporary fixing member to obtain a member to be laminated; (3) A module lamination step of laminating the member to be laminated, and allowing the sealing material (4) that has flowed out during lamination to enter the gap between the frame (1) and the module body (2) to complete the sealing of the module and the adhesion between the L-shaped frame and the module body (2); (4) A post-lamination treatment step of performing subsequent production of the module and removing the temporary fixing member, including: A method for manufacturing a lightweight frame solar power generation module according to claim 11, characterized in that.

13. The method for manufacturing a lightweight frame solar power generation module according to claim 11 or 12, characterized in that the temporary fixing member is an adhesive tape.

14. The method for manufacturing a lightweight frame solar power generation module according to claim 13, characterized in that the adhesive tape is a high-temperature resistant adhesive tape (3) that can withstand a temperature equal to or higher than the lamination temperature.

15. First, the L-shaped frames are integrally combined and fixed, and then the integrally combined and fixed L-shaped frames are placed on the laminated member, thereby realizing the assembly of the L-shaped frame and the laminated member. A method for manufacturing a lightweight frame solar power generation module according to claim 10, characterized in that.

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