DE102010050249A1 - Carrier module for photovoltaic cell, has base plate whose regions are projected between heat carrier channels in edge area, where edge area of base plate is material-lockingly connected with slab - Google Patents

Abstract

The module (10) has with a base plate e.g. deep-drawing part (12), with molded heat carrier channels (121). The base plate comprises regions (124, 125) that are projected between the channels in an edge area (126). The edge area of the base plate is material-lockingly connected with a slab. The material-lockingly connection is formed by roll seam welding seams, tungsten inert gas welding seams and/or metal active gas welding seams. The base plate, the slab and connection pieces i.e. metal sheet depositors, are made from light metal or light metal alloy e.g. aluminum or aluminum alloy. An independent claim is also included for a device for manufacturing a carrier module.

Description

The invention relates to a carrier module through which a heat carrier flows, in particular a carrier module for photovoltaic cells, and to a method and a device for producing such a carrier module.

From the DE 298 10 238 U1 is a support module for photovoltaic cells is known in which a wavy lamellar body made of aluminum is disposed on the underside of the photovoltaic cells, the wave troughs form channels for the liquid heat carrier, which comes to cool the photovoltaic cells in direct contact with the bottom. In the WO2007 / 144113 A1 the lamellar body made of aluminum is replaced by a tempering device made of plastic, whose liquid channels also directly adjacent to the underside of the photovoltaic cells.

The invention has the object of developing an aforementioned carrier module such that it has an increased load capacity and process reliable in liquid quantities is produced in large quantities.

The object is achieved in the support module mentioned above according to the invention that the support module is double-walled by a metal floor pan with molded heat transfer channels and a cover plate as stiffening plate, wherein the cover plate at between the heat transfer channels arranged raised intermediate areas and circumferentially in the edge regions of the bottom tray materially this is connected. The material-locking connection in the intermediate regions and in the edge regions is preferably carried out by laser welding. Alternatively, a connection by roll seam welding is possible.

The carrier module is provided in particular as a support for arranged on the side of the cover plate (or the stiffening plate) photovoltaic cells, but can also be used, for example, provided with a black finish, advantageously exclusively for hot water production as a pure solar heat exchanger.

Advantageous embodiments of the invention are specified in the subclaims.

Advantageously, the bottom pan is deep-drawn from a deep-drawn sheet, wherein alternately the raised edge regions and the raised intermediate regions with the interposed recessed heat transfer channels are formed directly with.

Preferably, transversely to the heat transfer channels extending collection and distribution channels are provided at the upper and at the lower edge of the bottom pan, which are closed in the lateral edge regions by preferably soldered fittings. Preferably, at least one connection fitting, for example in the form of a nut welded into the sheet metal insert, is integrated in the connecting pieces, which are preferably in the form of sheet metal inserts.

A particularly preferred embodiment provides that the carrier module according to the invention is produced in a device in which the stiffening sheet is clamped with the bottom tray placed thereon against a bulging, preferably formed by a plurality of curved clamping strips support of the device, wherein the protrusion is formed so that In the following, the carrier module and the device for its production will be explained in more detail by means of an exemplary embodiment with reference to the drawing, which explains the distortion which is unavoidable during subsequent welding. It shows:

1 a plan view of the inside of the floor pan;

2 a top perspective view of the carrier module from the outside of the bottom tray;

3 in enlarged view according to detail B from 2 the end of a collection and distribution channel prior to insertion of the fitting;

4 in an enlarged side view the end of a collection and distribution channel with the fitting inserted therein;

5 a plan view of a connector;

6 a section through the connector according to the section line VI-VI in 5 ;

7 a perspective partial view of a corner region of the inside of the floor pan;

8th - 11 the sequence in the production of welded joints between floor pan and cover plate;

12 a partial view of an empty tool for the production of a carrier module;

13 a further partial view of the tool with it received carrier module; and

14 a schematic partial section through a photovoltaic cell panel.

That in the 1 - 11 illustrated carrier module 10 essentially consists of a base tray designed as a deep-drawn sheet metal part 12 and a cover plate formed as a stiffening plate, mounted thereon 14 educated.

In the floor pan 12 are during deep drawing a plurality of parallel arranged, preferably uniformly spaced from each other heat transfer channels 121 molded, between which elongated raised areas 124 to form a separation. The heat transfer channels 121 open on both sides in perpendicular to it in two opposite edge areas 126 the floor pan 12 extending collection and distribution channels 122 out. Additional short raised areas 125 are at the junction of the heat transfer channels 121 in front of the collection and distribution channels 122 on a parallel line to the collection and distribution channels 122 on the floor pan 12 educated. Laterally outwards to the collection and distribution channels 122 then as well as to the outer of the heat transfer channels 121 adjacent are raised border areas 126 on the floor pan 12 educated. All sublime areas 124 . 125 and 126 serve to produce a cohesive or material connection between the floor pan 12 and she in the sublime areas 124 . 125 and 126 touching cover plate 14 ,

The end areas 123 the in cross section in approximately semicircular collection and distribution channels 122 are expanded, as in the 1 . 2 and 8th to 11 recognizable. These extended end areas 123 serve to accommodate fittings 16 , These fittings 16 are preferred as sheet metal depositors 161 trained in detail in the 3 to 6 are shown. The as a sheet feeder 161 trained fittings 16 have a vertical wall 162 with a bore in which an internal thread 167 having a mother 166 by means of a laser weld 169 welded or soldered. The vertical wall 162 of the sheet feeder 161 is at her in 5 upper edge to a horizontal wall 164 folded inwards. The rest of the arcuate edge region is in the same way to a fold 163 bent inwards at right angles ( 6 ). The lateral edges of the horizontal wall 164 meet in the end areas 165 with the ends of the fold 163 together, being the horizontal wall 164 on both sides has a slight projection to as far as possible the complementary contour of the end portion 123 adapt as the fittings 16 after fixing by means of the welds 24 ( 11 ) and after brazing the end portions 123 the collection and distribution channels 122 must complete completely liquid-tight. The mother 166 is outward slightly above the vertical wall 162 before and thereby forms a covenant to the plant one on one in the thread 167 screwed fitting arranged seal.

For the production of the carrier module 10 becomes the cover plate 14 with its later top down into one in the 12 and 13 illustrated tool 30 inserted, with several spaced, curved clamping strips 301 forms a three-dimensional arched support. The three-dimensional curvature serves to compensate for the sweat-induced distortion in the connection of the cover plate 14 with the floor pan 12 , The buckle is for a carrier module 10 with the outer dimensions of 1200 mm × 900 mm designed so that the center of the support is about 20 mm lower than the corners and the center of the larger, 1200 mm long sides is about 5 mm lower than the corners. The floor pan 12 and the sheet metal depositors 161 consist of about 0.8 mm thick bare deep-drawn sheet, while the cover plate 14 is formed by a sheet metal plate about 1.5 mm thick. Welding in the tool 30 takes place from the thinner material of the floor pan 12 to the thicker material of the cover plate 14 ,

The floor pan 12 is with its top down on the cover plate 14 hung up, so that their sublime areas 124 . 125 and the border area 126 on the cover plate 14 hang up. Then the tool becomes 30 closed, wherein a plurality of mutually parallel, in the inner region evenly spaced clamping bars 303 the floor pan 12 against the through the clamping strips 301 supported cover plate 14 to press. In the illustrated embodiment, a total of seven clamping bars 303 provided in the 8th to 11 and 13 numbered L1-L7. The tension bars 303 are preferred for a fine adjustment or readjustment of the local contact pressures with pressure bolts 304 provided by in the clamping bars 303 provided threads for height adjustment are rotatable and can be fixed if necessary by means of lock nuts in the set positions.

The tension bars 303 can with a simple tool 30 by means of collets 302 be moved manually in their Andrückposition. In a more advanced tool for higher volumes are the clamping bars 303 preferably moved by an electric motor, pneumatically or hydraulically. In this case, the tool becomes 30 also preferably by a handling robot, not shown, with the components 12 . 14 and 16 laden or with the finished carrier module 10 discharged.

Between the clamping strips 301 are in the embodiment according to 12 all in all sixteen pneumatic suction devices 305 arranged, which is the carrier module 10 in the last manufacturing step after loosening the clamping bars 303 hold in position. In 13 shown, preferably magnetic positioning devices 305 serve for the exact positioning of the connection pieces 16 before their welding or soldering in the end areas 123 the collection and distribution channels 122 ,

In a method according to the invention for producing a carrier module 10 First, the cover plate 14 as described above, opposite to its later position of use turned over into the tool 30 inserted. Lateral stops ensure a defined position of the cover plate 14 , Subsequently, the already deep-drawn floor pan 12 with its underside facing upwards on the cover plate 14 hung up. To close the tool 30 In the example shown, seven clamping bars will be used 303 down against the floor of the floor pan 12 pressed. Take cover plate 14 and floor pan 12 temporarily from the clamping strips 301 given three-dimensional curved contour.

In the 8th to 11 is a particularly advantageous sequence of process steps in applying the welds 18 . 20 . 22 . 24 and when removing the clamping bars step by step 303 shown. This will be described below.

In 8th are the cover plate 14 and the floor pan 12 in the tool 30 inserted and the fittings 16 are by means of the positioning devices 305 in the end areas 123 the collection and distribution channels 122 positioned.

In the first method step S01, first in 8th Starting from the bottom left using the in 13 represented, preferably guided by a robot laser welding system 40 two short welds 24 for fixing the located there, from the positioning device 305 held connector 16 from the outside to the end area 123 the floor pan 12 applied. Then, from bottom to top, the left raised areas 125 the bottom tray with short welds 24 Mistake.

Arrived at the top left in step S02 for fixing the left upper connector 16 the two short welds 24 on the end area 123 the floor pan 12 applied.

The laser welding system 40 is moved up to the right and welded in step S03, the two short welds 24 for fixing the right upper connection piece 16 , Then, from the top to the bottom, the right raised areas 125 the floor pan 12 with short welds 24 Mistake.

Arrived at the bottom right in step S04 for fixing the right lower fitting 16 the two short welds 24 on the end area 123 the floor pan 12 applied.

The laser welding system 40 is moved down to the left and welded in step S05 successively from bottom to top of the raised areas 124 each between the clamping bars L2 and L3 with the weld sections of the welds 20 ,

For the method step S06, the laser welding system 40 moves up to the right and welded from top to bottom of the weld sections 20 in the spaces between the clamping bars L3 and L4.

For the method step S07, the laser welding system 40 moves down to the right and welded from bottom to top the weld sections 20 in the spaces between the clamping bars L4 and L5.

For the method step S08, the laser welding system 40 moves up to the right and welded from top to bottom of the weld sections 20 in the spaces between the clamping bars L5 and L6.

Subsequently, the transition from the 8th to 9 the lifting bars L2, L3, L5 and L6 are lifted or removed. In step S09, the welds are made from top to bottom 20 added in the area in which previously was the clamping bar L5. Arrived at the bottom is the laser welding system 40 moves down to the left and welded from bottom to top the weld sections 20 in the area that was previously acted upon by the clamping bar L3.

Subsequently, in the process steps S11 and S12, the continuous dense longitudinal seams 18 on the outsides of the collection and distribution channels 122 on the raised edge areas 126 applied.

A general note on the term "raised areas" in the context of the reference numbers 124 . 125 and 126 designated areas of the floor pan 12 : The term "raised areas" refers to the position of use ( 4 or 7 ) of the carrier module 10 in which the cover plate 14 is arranged above. As 13 shows, the raised areas are due to the reverse position in the tool 30 there the lower lying areas.

Subsequently, at the transition from the 9 to 10 raised or removed the middle tension bar L4. In step S11 and S12, the continuous dense welds 18 on the upper and lower longitudinal sides of the floor pan 12 generated. Subsequently, in step S13 from bottom to top, the welds 20 added in the area in which previously was the clamping bar L4.

Finally, after activation of the suction devices 306 also raised or removed the last two remaining side clamping strips L1 and L7. This finally allows the fittings 16 if necessary still in the same tool 30 brazed or welded tight. The soldering process for the fittings 16 However, to shorten the production cycle also outside the welding device 30 respectively. In 11 is the completely finished carrier module 10 with all welds 18 . 20 . 22 and 24 shown.

By means of the method according to the invention described above using the welding device according to the invention 30 the three-dimensional protrusion is at least almost completely compensated by the sweat-induced distortion in the workpiece. The finished carrier module 10 This is essentially the same.

The carrier module 10 is then subjected to a cathodic dip paint coating. The KTL coating serves as a secure primer for subsequent PU foaming 56 for fixing the photovoltaic cells 52 and the glass pane covering this to the outside 54 , When using a stainless steel sheet ("Nirosta") for the production of the carrier module 10 becomes the carrier module 10 treated with a primer as a primer before applying the PU foam.

The carrier module 10 is preferred after completion as a carrier for in 14 illustrated photovoltaic cells 52 used on the top of the stiffening plate or cover plate 14 arranged, by means of a transparent, weather-resistant disc 54 covered up and by the PU foam 56 permanently with the carrier module 10 connected. Through the cover plate 14 get the photovoltaic cells 52 in contrast to the initially acknowledged prior art, a full-surface support, whereby one with the carrier module according to the invention 10 equipped photovoltaic cell panel 50 significantly more resistant to snow loads and hailstorm.

The heat transfer channels 121 be via the collection and distribution channels 212 evenly supplied with a liquid heat transfer medium (usually water with an antifreeze and / or corrosion inhibitor). Several adjacent photovoltaic cell panels 50 can easily through the connectors 16 be connected liquid-tight together by means of suitable connectors.

LIST OF REFERENCE NUMBERS

10

carrier module

12

floor pan

121

Heat carrier channel

122

Collection and distribution channel

123

End area (from 122 )

124

(raised) area

125

(raised) area

126

Border area (from 12 )

14

Stiffening plate (cover plate)

16

connector

161

sheet inserter

162

(vertical) wall (from 161 )

163

Fold (on 161 )

164

(horizontal wall) (from 161 )

165

end

166

mother

167

thread

168

Covenant (at 166 )

169

Weld

18

Weld (up 126 )

20

Weld (up 124 )

22

Weld (up 125 )

24

Weld (up 123 )

30

Welding device (tool)

301

Clamping strips (curved support; 30 )

302

collet

303

clamping bar

304

pushpin

305

Positioning device (for 16 )

306

suction device

40

Laser welding system

50

Photovoltaic cell panel

52

photovoltaic cells

54

cover plate

56

PU foam casing

L1-L7

clamping bars

S01-S13

steps

QUOTES INCLUDE IN THE DESCRIPTION

This list of the documents listed by the applicant has been generated automatically and is included solely for the better information of the reader. The 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

• DE 29810238 U1 [0002]
• WO 2007/144113 A1 [0002]

Claims (15)

Carried by a heat carrier carrier module ( 10 ), in particular carrier module ( 10 ) for photovoltaic cells, with a floor pan ( 12 ) with molded heat transfer channels ( 121 ), which are in their peripheral area ( 126 ) and between the heat transfer channels ( 121 ) raised areas ( 124 ; 125 ), characterized in that between the heat transfer channels ( 121 ) arranged raised areas ( 124 ; 125 ) of the floor pan ( 12 ) and the border area ( 126 ) of the floor pan ( 12 ) circumferentially with a cover plate arranged thereon ( 14 ) are materially connected to this. Carrier module according to claim 1, characterized in that the material-locking connection is effected by laser welding. Carrier module according to claim 1, characterized in that the material-locking connection is effected by seam welding. Carrier module according to at least one of the preceding claims, characterized in that the carrier module ( 10 ) near its edge region ( 126 ) longitudinal collection and distribution channels ( 122 ), which at their ends by connecting pieces ( 16 ) are closed. Carrier module according to claim 4, characterized in that the connecting pieces ( 16 ) fixed by welding and sealed between floor pan ( 12 ) and cover plate ( 14 ) are soldered. Carrier module according to at least one of claims 4 to 5, characterized in that the connecting pieces ( 16 ) as a sheet feeder ( 161 ) are formed. Carrier module according to at least one of claims 4 to 6, characterized in that in the connecting pieces ( 16 ) at least one connection fitting, in particular in the form of a in the sheet metal insert ( 161 ) welded nut ( 166 ) is integrated. Carrier module according to at least one of the preceding claims, characterized in that the material thickness of the sheet of the floor pan ( 12 ) and the fittings ( 16 ) about 0.8 mm and the cover plate ( 14 ) is about 1.5 mm. Device for producing a carrier module ( 10 ) according to one of the preceding claims, characterized by • below the cover plate ( 14 ) arranged clamping strips ( 301 ), which define a three-dimensional arched support, • several transverse to the clamping strips ( 301 ) arranged clamping strips ( 303 ), which are spaced apart from each other via the outside of the cover plate ( 14 ) floor pan ( 12 ) and the floor pan ( 12 ) against the cover plate ( 14 ) and the clamping strips ( 301 ), • at least one welding system, in particular a laser welding system, for the linear connection of the floor pan ( 12 ) with the cover plate ( 14 ), Whereby, depending on the progress of the welded joint, the clamping strips ( 303 ) are removable individually or in groups. Apparatus according to claim 9, characterized in that the greatest bulge depth in a carrier module ( 10 ) with the dimensions 1200 mm × 900 mm in the middle of the support opposite the corners is about 20 mm. Device according to one of claims 9 or 10, characterized in that the greatest bulging depth in a carrier module with the dimensions 1200 mm × 900 mm in the middle of the longitudinal sides of the support is about 5 mm with respect to the corners. Method for producing a carrier module ( 10 ) according to any one of claims 1 to 8, characterized by the following method steps • producing a floor pan ( 12 ) with recessed channels ( 121 ; 122 ) and raised welding areas ( 124 ; 125 ; 126 ) by deep drawing, • producing a flat cover plate ( 14 ) with the floor pan ( 12 ) matching outer dimensions, • inserting the cover plate ( 14 ) into a device ( 30 ) with a three-dimensional arched receptacle, • placing the floor pan ( 12 ) on the cover plate ( 14 ), • Pressing the floor pan ( 12 ) against the cover plate ( 14 ) and the recording, • sequential application of several line-shaped welds ( 18 ; 20 ; 22 ; 24 ) between the raised welding areas ( 124 ; 125 ; 126 ) of the floor pan ( 12 ) and the cover plate ( 14 ), Wherein the curvature of the recording compensates for the sweat-induced distortion of the carrier module such that the finished carrier module ( 10 ) is largely flat. Method according to claim 12, characterized in that the welds ( 18 ; 20 ; 22 ; 24 ) are generated by a laser welding process. Method according to one of claims 12 to 13, characterized in that on the floor pan ( 12 ) provided collection and distribution channels ( 122 ) by inserted connecting pieces ( 16 ), which after placing and pressing the floor pan ( 12 ) by means of a positioning device ( 305 ) in the ends of the collection and distribution channels ( 122 ) and then through at least one weld ( 24 ) at least opposite the floor pan ( 12 ) are fixed. Method according to claim 14, characterized in that the connecting pieces ( 16 ) after fixing by means of the at least one weld ( 24 ) by brazing completely close to the bottom pan ( 12 ) and the cover plate ( 14 ) get connected.

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