Steel frame for photovoltaic module and manufacturing method thereof

Abstract

According to the present disclosure, a steel frame for a photovoltaic module is formed by bending a single alloy-plated steel sheet, and comprises a frame member having an insertion part into which a photovoltaic panel is inserted and a cavity part forming a closed cross-section. The alloy-plated steel sheet comprises an Mg-Al-Zn-based plating layer on the surface of a steel sheet having a yield strength of 280-350 MPa.

Description

Solar module steel frame and manufacturing method

[0001] The present disclosure relates to a solar module steel frame and a manufacturing method.

[0002] In general, solar modules are power generation devices used outdoors and require durability under very harsh conditions such as ultraviolet rays, wind and snow, salt damage, acid rain, freezing, pollution deposition, and microbial growth.

[0003] These solar modules are primarily installed outdoors, so they incorporate square frames to ensure rigidity. While solar module frames utilize extruded aluminum to provide a shape optimized for solar modules, they suffer from the following drawbacks. First, the low elongation of the material can lead to brittle fracture when exposed to high loads, such as typhoons. Furthermore, the difference in surface potential between the extruded aluminum and the galvanized steel, which is typically used as a substructure, can lead to galvanic corrosion. Furthermore, extruded aluminum generates significant carbon emissions during the raw material extraction and processing process. While aluminum frames account for 8-13% of the total weight of a finished solar module, their carbon emissions account for 15-20% of the module's total. Furthermore, aluminum's raw material price volatility significantly impacts the stability of module suppliers' product supply.

[0004] One aspect of the present disclosure is to provide a solar module steel frame and a manufacturing method capable of securing strength and rigidity equivalent to or greater than that of an aluminum frame.

[0005] According to an embodiment of the present disclosure, a solar module steel frame can be provided, which comprises a frame member formed by bending a single alloy-plated steel sheet, having an insertion portion into which a solar panel is inserted and a hollow portion forming a closed cross-section, wherein the alloy-plated steel sheet has a yield strength of 280 to 350 MPa and includes a Mg-Al-Zn-based plating layer on the surface of the steel sheet.

[0006] The above plating layer may include Mg: 2.5 to 3.5 (%), Al: 2.0 to 3.0 (%), and the remainder Zn based on the mass ratio.

[0007] The above frame member may be provided with a double sheet structure in which the cross section, excluding the portion forming the common portion, is made up of an outer panel and an inner panel overlapping each other.

[0008] The above frame member includes an upper frame portion located above the insert portion and a lower frame portion extending from the lower surface of the common portion, and a hemming joint may be provided in the upper frame portion.

[0009] The above hemming joint may be provided with a plurality of clinching joints.

[0010] An adhesive sealant may be provided between the insert and the solar panel.

[0011] The above frame member includes an upper frame portion located above the insert portion and a lower frame portion extending from the lower surface of the common portion, and a hemming joint may be provided in the lower frame portion.

[0012] The above hemming joint may be provided with a plurality of clinching joints.

[0013] The frame member includes a long-side frame member and a short-side frame member, and further includes a corner key member including a first panel inserted into a common portion of the long-side frame member to connect corners of the long-side frame member and the short-side frame member, and a second panel intersecting the first panel and inserted into the common portion of the short-side frame member.

[0014] The above corner key member may have a C-shaped cross-section.

[0015] The above frame member may be provided with a partially deformed and sunken catch, and the corner key member may be provided with a catch hole in which the catch is caught.

[0016] The above corner key member can be made of the same material as the above frame member.

[0017] In another aspect, according to one embodiment of the present disclosure, in a method for manufacturing a solar module steel frame, a method for manufacturing a solar module steel frame can be provided in which the frame member is manufactured using a roll forming processing process.

[0018] A jig device including a pressing jig provided with a hook forming projection, an insertion jig provided with a projection insertion groove corresponding to the hook forming projection, and a disassembly jig for supporting the insertion jig is prepared, and the insertion jig and the disassembly jig are inserted into the cavity, and the pressing jig is brought into pressurized contact with the frame member using a press machine to form the hooking portion.

[0019] After the above-mentioned catch portion is formed, the dismantling jig can be withdrawn from the above-mentioned cavity.

[0020] According to one embodiment of the present disclosure, by using an alloy-plated steel having excellent corrosion resistance and yield strength, structural stability and durability equivalent to or greater than that of an aluminum frame can be secured.

[0021] Additionally, according to one embodiment of the present disclosure, it is possible to reduce carbon emissions compared to applying an aluminum frame.

[0022] FIG. 1 is a perspective view illustrating a solar module according to one embodiment of the present disclosure.

[0023] FIG. 2 is a cross-sectional view of a frame member according to one embodiment of the present disclosure.

[0024] FIG. 3 is a perspective view of a frame member according to one embodiment of the present disclosure.

[0025] FIG. 4 is a cross-sectional view showing a state in which a solar panel according to one embodiment of the present disclosure is coupled to a frame member.

[0026] FIG. 5 is a cross-sectional view of a frame member according to another embodiment of the present disclosure.

[0027] FIG. 6 is a perspective view of a frame member according to another embodiment of the present disclosure.

[0028] FIG. 7 is an exploded perspective view illustrating a corner joint portion of a solar module steel frame according to one embodiment of the present disclosure.

[0029] FIG. 8 is a perspective view illustrating a corner key member according to one embodiment of the present disclosure.

[0030] FIG. 9 is a perspective view illustrating a corner key member according to another embodiment of the present disclosure.

[0031] FIG. 10 is a cross-sectional view illustrating a connection portion between a corner key member and a frame according to one embodiment of the present disclosure.

[0032] Fig. 11 is a perspective view illustrating a jig device according to one embodiment of the present disclosure.

[0033] FIG. 12 is a drawing showing the operating state of a jig device according to one embodiment of the present disclosure.

[0034] FIG. 13 is a drawing showing a state in which a dismantling jig of a jig device according to one embodiment of the present disclosure is separated.

[0035] The embodiments described in this specification are only the most preferred embodiments of the present invention and do not represent all of the technical ideas of the present invention. Therefore, it should be understood that various equivalents or modified examples that can replace them at the time of filing this application are also included in the scope of the rights of the present invention.

[0036] Additionally, the same reference numbers or symbols presented in each drawing of the present disclosure represent parts or components that perform substantially the same function.

[0037] In addition, the terminology used in this disclosure is used to describe embodiments and is not intended to limit and / or restrict the disclosure. Singular expressions include plural expressions unless the context clearly indicates otherwise. In this disclosure, terms such as “comprise” or “have” are intended to indicate the presence of a feature, number, step, operation, component, part, or combination thereof described in the disclosure, but do not preclude the presence or addition of one or more other features, numbers, steps, operations, components, parts, or combinations thereof.

[0038] Additionally, terms including ordinal numbers such as “first,” “second,” etc. used in the present disclosure may be used to describe various components, but the components are not limited by the terms, and the terms are used only for the purpose of distinguishing one component from another. For example, without departing from the scope of the present disclosure, the first component may be referred to as the second component, and similarly, the second component may also be referred to as the first component. The term “and / or” includes any combination of a plurality of related listed items or any item among a plurality of related listed items.

[0039] Furthermore, the meaning of "identical" in this disclosure includes having similar properties or being similar within a certain range. Furthermore, "identical" means "substantially identical." "Substantially identical" should be understood to include values ​​that fall within the manufacturing error range or values ​​that differ from a reference value within a range that has no significance.

[0040] Additionally, terms such as "~part", "~device", "~block", "~absence", and "~module" may refer to a unit that processes at least one function or operation. For example, the terms may refer to at least one hardware such as an FPGA (field-programmable gate array) / ASIC (application specific integrated circuit), at least one software stored in a memory, or at least one process processed by a processor.

[0041] Singular expressions include plural expressions unless the context clearly indicates otherwise.

[0042] Meanwhile, the terms “front,” “rear,” “left,” and “right” used in the description below are defined based on the drawing, and the shape and position of each component are not limited by these terms.

[0043] Hereinafter, preferred embodiments according to the present disclosure will be described in detail with reference to the attached drawings.

[0044] FIG. 1 is a perspective view illustrating a solar module according to one embodiment of the present disclosure.

[0045] Referring to FIG. 1, a solar module (10) according to one embodiment of the present disclosure may include a solar panel (11) and a solar module steel frame (20) coupled to the frame of the solar panel (11).

[0046] The solar module steel frame (20) may include a frame member (30, 40) that is joined to the frame of the solar panel (11).

[0047] The frame member (30, 40) includes a pair of long-side frame members (30) that wrap around the long sides of the solar panel (11) and a pair of short-side frame members (40) that wrap around the short sides of the solar panel (11), and the pair of long-side frame members (30) and the pair of short-side frame members (40) can be connected to each other by a corner key member (50).

[0048] The frame members (30, 40) and the corner key members (50) can be formed by bending an alloy-plated steel plate. The alloy-plated steel plate can include a Mg-Al-Zn-based plating layer on the surface of a steel plate having a yield strength of 280 to 350 MPa, taking into account the influence of local buckling and processing load. This plating layer can include Mg: 2.5 to 3.5 (%), Al: 2.0 to 3.0 (%), and the remainder Zn, based on the mass ratio. Through this, strength and rigidity equivalent to or higher than that of an existing aluminum frame can be secured. In addition, since the frame members (30, 40) and the corner key members (50) are manufactured from the same material, corrosion caused by a potential difference between the two materials can be prevented.

[0049] FIG. 2 is a cross-sectional view of a frame member according to one embodiment of the present disclosure, FIG. 3 is a perspective view of a frame member according to one embodiment of the present disclosure, and FIG. 4 is a cross-sectional view showing a state in which a solar panel according to one embodiment of the present disclosure is coupled to a frame member.

[0050] Referring to FIGS. 2 to 4, the frame members (30, 40) can be manufactured through roll forming of an alloy-plated steel plate.

[0051] The long-side frame member (30) and the short-side frame member (40) constituting the frame member (30, 40) can each be configured with the same cross-sectional shape.

[0052] The frame member (30, 40) may include an insertion portion (60) into which a solar panel (11) is inserted and a cavity portion (70) forming a closed cross-section. The insertion portion (60) and the cavity portion (70) may be formed by bending a single alloy-plated steel plate multiple times through roll forming.

[0053] The frame member (30, 40) may be provided with a double sheet structure in the cross section except for the portion forming the common part (70) to reinforce strength.

[0054] The frame member (30, 40) may include an upper frame portion (21), a side wall frame portion (22), a common frame portion (23), and a lower frame portion (24).

[0055] The upper frame portion (21), the side wall frame portion (22), and the lower frame portion (24) may each be provided with a double sheet structure in which the outer panel and the inner panel overlap, and the common frame portion (23) forming the common portion (70) may be provided with a single sheet structure.

[0056] The upper frame portion (21) can be positioned on the upper side of the insert portion (60), and the side wall frame portion (22) can be positioned on the side of the insert portion (60). The insert portion (60) can be formed by the upper frame portion (21), the side wall frame portion (22), and the upper surface (23a) of the common frame portion (23).

[0057] A hemming joint (80) may be provided in the upper frame portion (21). The hemming joint (80) may be formed by bending the end of the outer panel (21a) of the upper frame portion (21) so as to overlap the inner side of the inner panel (21b).

[0058] A plurality of clinching joints (90) may be provided in the hemming joint (80). The hemming joint (80) and the inner panel (21b) of the upper frame portion (21) may be joined through a clinching process while overlapping each other.

[0059] An adhesive sealant (100) may be filled between the solar panel (11) and the insertion portion (60). At this time, the hemming joint (80) provided in the upper frame portion (21) may help facilitate the filling of the adhesive sealant (100) into the insertion portion (60). The adhesive sealant (100) may evenly transfer the load of the solar panel (11) to the frame member (30, 40) through the adhesive and cushioning action of the solar panel (11) to the insertion portion (60).

[0060] The joint frame portion (23) may include an upper surface (23a) forming the lower side of the insertion portion (60) and the upper side of the joint portion (70), both sides (23b, 23c) forming both sides of the joint portion (70), and a lower surface (23d) forming the lower side of the joint portion (70). This joint frame portion (23) may be provided in a single sheet structure.

[0061] The lower frame portion (24) can extend inward (toward the solar panel) from the lower surface (23d) of the common frame portion (23). The lower frame portion (24) can be provided with a double sheet structure in which an inner panel (24b) and an outer panel (24a) overlap.

[0062] These frame members (30, 40) can be manufactured by sequentially forming them by roll forming starting from the inner panel (21b) of the upper frame part (21) forming the upper portion of the insertion part (60), the inner panel (22b) of the side wall frame part (22), the upper surface (23a) of the cavity part (70), one side surface (23b) of the cavity part (70), the inner panel (24b) of the lower frame part (24), the outer panel (24a) of the lower frame part (24), the lower surface (23d) of the cavity part (70), the other side surface (23c) of the cavity part (70), the outer panel (22a) of the side wall frame part (22), the outer panel (21a) of the upper frame part (21), and the hemming joint (80).

[0063] FIG. 5 is a cross-sectional view of a frame member according to another embodiment of the present disclosure, and FIG. 6 is a perspective view of a frame member according to another embodiment of the present disclosure. In the following, identical components are assigned the same reference numerals, and detailed descriptions thereof are omitted.

[0064] Referring to FIGS. 5 and 6, a frame member (30, 40) according to another embodiment of the present disclosure is the same as the above-described embodiment, except that a hemming joint (81) is provided in the lower frame portion (24).

[0065] Specifically, a hemming joint (81) may be provided in the lower frame portion (24). The hemming joint (81) may be formed by bending the end of the outer panel (24a) of the lower frame portion (24) so ​​as to overlap the inner side of the inner panel (24b). A plurality of clinching joints (91) may be provided in the hemming joint (81) provided in the lower frame portion (24). The plurality of clinching joints (91) may be formed by a clinching process in a state where the hemming joint (81) and the inner panel (24b) of the lower frame portion (24) overlap each other.

[0066] These frame members (30, 40) can be manufactured by sequentially forming them by roll forming starting from the inner panel (24b) of the lower frame part (24), one side (23b) of the cavity part (70), the upper surface (23a) of the cavity part (70), the inner panel (22b) of the side wall frame part (22), the inner panel (21b) of the upper frame part (21), the outer panel (21a) of the upper frame part (21), the outer panel (22a) of the side wall frame part (22), the other side (23c) of the cavity frame part (23), the lower surface (23d) of the cavity frame part (23), the outer panel (24a) of the lower frame part (24), and the hemming joint (81).

[0067] FIG. 7 is an exploded perspective view illustrating a corner joint portion of a solar module steel frame according to one embodiment of the present disclosure, FIG. 8 is a perspective view illustrating a corner key member according to one embodiment of the present disclosure, FIG. 9 is a perspective view illustrating a corner key member according to another embodiment of the present disclosure, and FIG. 10 is a cross-sectional view illustrating a connection portion between a corner key member and a frame according to one embodiment of the present disclosure.

[0068] Referring to FIGS. 7 to 10, a corner key member (50) according to one embodiment of the present disclosure may include a first panel (51) and a second panel (52) that are arranged to intersect each other. The corner key member (50) may be provided as an 'L'-shaped angle member. The first panel (51) and the second panel (52) may be provided as members having a C-shaped cross-section or a U-shaped cross-section. As illustrated in FIG. 8, the first and second panels (51) and the second panels (52) that intersect each other may be joined to each other by welding. Alternatively, as illustrated in FIG. 9, the first and second panels (51) and the second panels (52) that intersect each other may be formed by bending a single member.

[0069] The first panel (51) can be inserted into the cavity (70) of the long-side frame member (30), and the second panel (52) can be inserted into the cavity (70) of the short-side frame member (40).

[0070] The first panel (51) may include a first contact panel (51a) that contacts one side (23b) of the cavity (70) of the long-side frame member (30), and a pair of first flanges (51b) that are bent at each end of the first contact panel (51a). When inserted into the cavity (70) of the long-side frame member (30), the pair of first flanges (51b) may contact the upper surface (23a) and the lower surface (23d) of the cavity (70) of the long-side frame member (30).

[0071] The second panel (52) may include a second contact panel (52a) that contacts one side (23b) of the hollow portion (70) of the single-sided frame member (40), and a pair of second flanges (52b) that are bent at each end of the second contact panel (52a). When inserted into the hollow portion (70) of the single-sided frame member (40), the pair of second flanges (52b) may contact the upper surface (23a) and the lower surface (23d) of the hollow portion (70) of the single-sided frame member (40).

[0072] At least one hook hole (53) may be formed through the first panel (51) and the second panel (52), respectively. The hook hole (53) may be provided in a rectangular or square shape. The hook hole (53) may be provided in the first contact panel (51a) and the second contact panel (52a), respectively. A hook portion (110) provided in the frame member (30, 40) may be hooked and supported through the hook hole (53).

[0073] The catch (110) may be provided in a form in which a part of the frame member (30, 40) is deformed and protrudes toward the cavity (70). The catch (110) may be positioned at a position corresponding to a portion of the frame member (30, 40) where the corner key member (50) is coupled. The catch (110) may be provided on one side (23b) of the frame member (30, 40) forming the cavity (70). The catch (110) may be formed integrally with the frame member (30, 40) by being recessed to a certain depth from one side (23b) of the frame member (30, 40) through press forming. The catch (110) may include an entry guide surface (111) and a catch surface (112). The entry guide surface (111) can extend obliquely from one side (23b) of the frame member (30, 40) toward the common portion (70), and the catch surface (112) can extend vertically from the end of the entry guide surface (111) to one side (23b) of the frame member (30, 40). When the corner key member (50) is inserted and coupled into the common portion (70) of the frame member (30, 40), the catch surface (112) of the catch portion (110) is caught and supported by the catch hole (53) of the corner key member (50), thereby allowing the corner key member (50) to be fastened to the frame member (30, 40).

[0074] The catch (110) provided on the frame member (30, 40) can be manufactured using a jig device. Hereinafter, a method for manufacturing the catch (110) on the frame member (30, 40) will be described.

[0075] FIG. 11 is a perspective view illustrating a jig device according to one embodiment of the present disclosure, FIG. 12 is a drawing illustrating an operating state of a jig device according to one embodiment of the present disclosure, and FIG. 13 is a drawing illustrating a state in which a disassembly jig of a jig device according to one embodiment of the present disclosure is separated.

[0076] Referring to FIGS. 11 to 13, a jig device (120) that forms a hook (110) on a frame member (30, 40) may include a pressing jig (121), an insertion jig (122), and a dismantling jig (123).

[0077] The pressing jig (121) may include a catch forming projection (121a). The pressing jig (121) is connected to a press machine (not shown) and can move downward by the operation of the press machine. The catch forming projection (121a) may be formed in a sawtooth shape. The pressing jig (121) may be positioned outside the cavity (70) of the frame member (30, 40). The pressing jig (121) may be positioned to face one side (23b) of the frame member (30, 40) forming the cavity (70) at a predetermined distance, and when lowered by the operation of the press machine, it may come into pressurized contact with one side (23b) of the frame member (30, 40).

[0078] The insertion jig (122) can be inserted into the cavity (70) of the frame member (30, 40). The insertion jig (122) can be brought into close contact with one side (23b) of the frame member (30, 40) from the inside of the cavity (70). The insertion jig (122) can include a first portion (122a) extending laterally so as to be in close contact with one side (23b) of the frame member (30, 40) from the cavity (70) and a second portion (122b) extending longitudinally from the outside of the cavity (70). A projection insertion groove (122c) corresponding to a catch-forming projection (121a) provided on the pressing jig (121) can be provided in the first portion (122a). The protrusion insertion groove (122c) can accommodate the catch forming protrusion (121a) while the pressing jig (121) presses one side (23b) of the frame member (30, 40).

[0079] The dismantling jig (123) can be inserted into the cavity (70) of the frame member (30, 40). The dismantling jig (123) can be provided to support the bottom of the insertion jig (122) inserted into the cavity (70), i.e., the bottom of the first portion (122a). The dismantling jig (123) can be interposed between the insertion jig (122) and the other side (23c) forming the cavity (70) within the cavity (70). The dismantling jig (123) can include a through hole (123a) through which a catch is hung to facilitate a withdrawal operation from the cavity (70).

[0080] Through this, in order to form a catch (110) in the frame member (30, 40), the first part (122a) of the insertion jig (122) and the dismantling jig (123) are inserted into the cavity (70) of the frame member (30, 40) as illustrated in FIG. 12. At this time, the second part (122b) of the insertion jig (122) can contact the end of one side (23b) of the frame member (30, 40). When the insertion jig (122) and the dismantling jig (123) are inserted into the cavity (70), the insertion jig (122) can be in close contact with one side (23b) of the frame member (30, 40), and the dismantling jig (123) can be in close contact with the other side (23c) of the frame member (30, 40).

[0081] When the insertion jig (122) and the dismantling jig (123) are inserted into the cavity (70), the pressing jig (121) is moved using a press machine to pressurize and contact one side (23b) of the frame member (30, 40), thereby creating a catch (110). Thereafter, as illustrated in FIG. 13, when the dismantling jig (123) is withdrawn from the cavity (70), the insertion jig (122) moves downward, so that the jig device (120) can be easily withdrawn from the cavity (70).

[0082] While the technical concept of the present invention has been described above through specific examples, the scope of the present invention is not limited to these examples. Various embodiments that can be modified or altered by those skilled in the art without departing from the spirit of the present invention as defined in the claims are also within the scope of the present invention.

Claims

1. A frame member formed by bending a single alloy-plated steel plate and having an insertion portion into which a solar panel is inserted and a hollow portion forming a closed cross-section, The above alloy-plated steel sheet is a solar module steel frame including a Mg-Al-Zn system plating layer on the surface of the steel sheet having a yield strength of 280 to 350 MPa.

2. In paragraph 1, A solar module steel frame, wherein the plating layer contains Mg: 2.5 to 3.5 (%), Al: 2.0 to 3.0 (%), and the remainder Zn based on mass ratio.

3. In paragraph 1, The above frame member is a solar module steel frame in which the cross-section, excluding the portion forming the above-mentioned common portion, is provided with a double sheet structure in which the outer panel and the inner panel are overlapped.

4. In paragraph 3, The above frame member includes an upper frame portion located above the insert portion and a lower frame portion extending from the lower surface of the cavity portion, A solar module steel frame having a hemming joint provided on the upper frame portion.

5. In paragraph 4, A solar module steel frame having a plurality of clinching joints provided at the above hemming joint.

6. In paragraph 4, A solar module steel frame having an adhesive sealant provided between the insert and the solar panel.

7. In paragraph 3, The above frame member includes an upper frame portion located above the insert portion and a lower frame portion extending from the lower surface of the cavity portion, A solar module steel frame having a hemming joint provided in the lower frame section.

8. In paragraph 7, A solar module steel frame having a plurality of clinching joints provided at the above hemming joint.

9. In paragraph 1, The above frame member includes a long-side frame member and a short-side frame member, A solar module steel frame further comprising a corner key member including a first panel inserted into a cavity of the long-side frame member to connect corners of the long-side frame member and the short-side frame member, and a second panel intersecting the first panel and inserted into the cavity of the short-side frame member.

10. In paragraph 9, The above corner key member is a solar module steel frame having a C-shaped cross-section.

11. In paragraph 9, The above frame member is provided with a partially deformed and sunken catch, A solar module steel frame in which a catch hole for catching the catch part is provided in the above corner key absence.

12. In paragraph 9, The above corner key member is a solar module steel frame made of the same material as the above frame member.

13. In the method for manufacturing the solar module steel frame of Article 11, The above frame member is a method for manufacturing a solar module steel frame using a roll forming process.

14. In paragraph 13, Prepare a jig device including a pressing jig provided with a catch forming projection, an insertion jig provided with a projection insertion groove corresponding to the catch forming projection, and a disassembly jig that supports the insertion jig. Insert the above insertion jig and the above disassembly jig into the above cavity, A method for manufacturing a solar module steel frame, wherein the pressing jig is pressed into contact with the frame member using a press machine to form the engaging portion.

15. In paragraph 14, A method for manufacturing a solar module steel frame, wherein the dismantling jig is pulled out from the cavity after the above-mentioned hanging portion is formed.

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