WO2021036273A1 - Frame for solar photovoltaic module and photovoltaic module - Google Patents
Frame for solar photovoltaic module and photovoltaic module Download PDFInfo
- Publication number
- WO2021036273A1 WO2021036273A1 PCT/CN2020/084110 CN2020084110W WO2021036273A1 WO 2021036273 A1 WO2021036273 A1 WO 2021036273A1 CN 2020084110 W CN2020084110 W CN 2020084110W WO 2021036273 A1 WO2021036273 A1 WO 2021036273A1
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- Prior art keywords
- frame
- photovoltaic module
- solar photovoltaic
- module
- closed cavity
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Images
Classifications
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
- H02S30/00—Structural details of PV modules other than those related to light conversion
- H02S30/10—Frame structures
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
Definitions
- the invention relates to the technical field of photovoltaic modules, in particular to a frame for solar photovoltaic modules and photovoltaic modules.
- a frame is installed around the periphery of the photovoltaic module, the edge of the solar cell laminate is accommodated in the notch of the frame, and the photovoltaic module is installed on the support through the frame.
- the frame of the photovoltaic module plays a role in enhancing the strength of the module and sealing the edge of the module.
- the thickness of photovoltaic glass has a tendency to gradually become thinner, and the thickness has changed from 3.2mm to 2.5mm, or even 2.0mm. According to different module types, it can be divided into single glass module and double glass module.
- the glass thickness of single glass module varies from 3.2mm to 2.8mm; the glass thickness of double glass module varies from 2.5+2.5mm to 2.0+2.0mm. Changes in component thickness also require frame design to follow up with the latest component thickness design requirements.
- the frames of existing photovoltaic modules are mostly made of aluminum alloy materials, which have the following disadvantages:
- the strength of the existing aluminum frame is limited. Throughout the history of the development of photovoltaic modules, the size of the module has changed from 250*175*25mm to the current 1950*995*45mm. The size of the module has increased a lot, and it will develop towards larger sizes in the future. As the module size becomes larger, the frame size of the aluminum photovoltaic module develops toward a larger frame cross section and thicker thickness. The essential reason for this phenomenon is the low strength of the aluminum material itself. When the module size becomes larger , The use of aluminum alloy materials to make the profile, the module frame section needs to be reinforced with a larger section and thicker structure, and a larger section and thicker structure will increase the use cost. 2.
- the existing aluminum frame has high transportation and storage costs. As the height of photovoltaic modules increases, that is, the module height changes from 25mm to the current 40mm or even larger, the packaging costs and transportation costs of photovoltaic modules have also increased, and the storage space of photovoltaic modules has also been restricted.
- the height limit of the junction box is reduced.
- the junction box is an important part of the photovoltaic module. It contains important components such as diodes or power switches.
- the design of the module frame must consider the influence of the junction box-the design height under the module frame is usually higher than the height of the junction box.
- the thickness of the junction box of the traditional technology is 20mm. With the development of technology, it has now reached 18mm. It can be seen that the height of the junction box does not affect the height of the module frame.
- the semiconductor chip is directly integrated with the junction box copper bar to make the wiring. The box is moving in a thinner direction. However, the height of the aluminum frame cannot be effectively reduced due to the low yield strength of the material, which is not conducive to reducing the cost of frame consumables and components.
- the purpose of the present invention is to overcome the shortcomings of the prior art and provide a frame for solar photovoltaic modules and photovoltaic modules.
- the present invention provides a frame for solar photovoltaic modules, and its technical solution includes:
- It includes a closed cavity, and an installation notch for installing photovoltaic modules is arranged above the closed cavity; and is characterized in that:
- the frame is formed by cold-rolled steel sheet or extrusion formed by alloy material
- a filling structure is provided in the closed cavity
- the frame is cold-formed by using steel plate or metal alloy plate as the base material, and the outer surface of the frame is provided with a corrosion-resistant metal coating, or protected by brushing paint; or,
- the frame is extruded and formed by using aluminum alloy or magnesium alloy as a base material, and the surface of the aluminum alloy or magnesium alloy is oxidized or protected by brushing paint.
- the left frame of the closed cavity extends upward to form a vertical frame, and the top of the vertical frame extends to the right to form a top frame;
- the lower frame of the closed cavity extends to the right to form a bottom frame
- the vertical frame, the top frame, and the upper frame of the cavity form the installation slot for installing the photovoltaic module.
- the top frame of the closed cavity extends rightward to form a lower frame, the lower frame extends upward to form a vertical frame, and the vertical frame extends to the left to form a top frame;
- the lower frame of the closed cavity extends to the right to form a bottom frame
- the bottom frame, the vertical frame, the top frame, and the upper frame of the cavity form the installation slot for installing the photovoltaic module.
- the surface of the steel or hard aluminum alloy sheet is plated with a corrosion-resistant coating, an oxidation coating or a paint coating, and the thickness of the metal sheet is 0.3-1.2 mm, preferably 0.4-0.6 mm.
- the foaming material is made of organic foaming material or inorganic foaming material.
- the foaming material is a rigid polyurethane foam plastic or an unsaturated polyester plastic
- the unsaturated polyester plastic includes two components A and B
- the A component includes an unsaturated polyester resin, a thickener, Initiator and filler
- component B is glass fiber grit or glass fiber mat.
- the vertical frame, the top frame, and the bottom frame are all rolled to form at least a two-layer structure.
- edge seam of the frame is rolled and occluded or welded to form a closed cavity.
- a filling structure is provided in the cavity of the frame for foaming.
- the inner connection of the long side and the short side of the frame is provided with a first connecting piece, the first connecting piece is detachably fixed on the bottom wall, and the first connecting piece is used for the same frame The connection between the long side and the short side on the top.
- a second connecting piece is provided at the outer connection of the long side and the short side of the frame, and the second connecting piece is used for the connection between adjacent frames.
- the outer sides of the long side and the short side of the frame are connected by welding, and the welding can be resistance welding, laser welding or cold welding.
- the present invention also provides a photovoltaic module, which includes the aforementioned frame for a solar photovoltaic module.
- the solar photovoltaic module frame provided by the present invention is suitable for single-sided modules and double-sided modules.
- the main structure of the module frame is made by selecting steel plates or metal alloy plates and adopting the process of cold-rolling forming, thereby greatly increasing the number of modules.
- the strength of the frame this is because the strength of the steel can reach more than three times the strength of the aluminum material, which fundamentally solves the problem of the strength of the module frame; and further provides a high-strength and good adhesiveness in the cavity of the module frame.
- Foam material to make the foam material and the steel component frame work together to further enhance the yield strength of the component frame.
- the steel sheet is used in the present invention, the steel sheet is cold-rolled into a module frame with a cavity, and at the same time, a foaming material is arranged in the cavity, which can greatly increase the strength of the module frame. Therefore, the present invention There is no need to set the height of the module frame higher to accommodate large-size photovoltaic modules, so that the thickness and weight of the module frame can be effectively reduced.
- the frame structure extruded by using aluminum alloy or magnesium alloy as the base material can also play a significant role in reinforcement.
- the height of the frame in the present invention is about 25mm.
- the frame of the present invention can be used for larger-specification modules without increasing The height of the border. Therefore, compared with the current module frame with a height of 45 mm, the module frame of the present invention can reduce the transportation cost by about 44%, and the storage space can save 44%. Its 4-point fixed installation method can save 50% of the number of press blocks.
- the present invention creatively uses the very light special effect of foaming materials to foam in the bent steel forming frame to form an integral frame with a honeycomb structure. Ensure the strength of the component frame without affecting the weight of the component frame.
- the extension length of the bottom wall is set to be greater than the extension length of the upper wall and the lower wall, so as to connect the integral frame with the purlin of the photovoltaic support, so that the module and the purlin can be directly connected instead of using the traditional pressing block to connect the purlin.
- the components are connected with the purlins of the photovoltaic support, saving installation materials and installation labor costs.
- Fig. 1 is a schematic structural diagram of a frame for a solar photovoltaic module according to an embodiment of the present invention.
- Fig. 2 is a schematic structural diagram of a frame for a solar photovoltaic module according to an embodiment of the present invention.
- Fig. 3 is a schematic diagram of the structure of the first connecting member of the present invention.
- Fig. 4 is a schematic diagram of the installation of the first connector of the present invention.
- Fig. 5 is a schematic diagram of the structure of the second connecting member of the present invention.
- Fig. 6 is a schematic diagram of the installation of the second connector of the present invention.
- Fig. 7 is a schematic diagram of the connection of the long side and the short side of the frame for the solar photovoltaic module of the present invention.
- Figure 8 is a finite element analysis diagram.
- Fig. 8 is a schematic diagram of the calculated cross section.
- Figure 10 is a finite element analysis diagram.
- plate rolling is a process of continuous three-point bending of the sheet metal using a plate rolling machine.
- the equipment puts the sheet between the upper and lower work rolls during the rolling.
- the upper roller is raised and lowered vertically, and the two lower rollers rotate and move horizontally relative to the axis of the upper roller.
- the continuous rotation of the bottom roller drives the steel plate to advance and retreat through the friction between the plate and the roller to complete the coiling.
- the entire process also includes operations such as pre-bending, centering, rounding, and rounding.
- foaming materials there are many types of foaming materials in the chemical industry. According to the hardness, they can be divided into soft, rigid and semi-rigid. According to the density, they can be divided into low-foaming foam, medium-foaming foam and high-foaming foam.
- Common foaming process methods such as intermittent foaming method, molded foaming method, extrusion foaming method, etc., extrusion foaming method is preferably used.
- the extrusion foaming method is to add the plastic material containing the foaming agent into the extruder, after the screw is rotated and the barrel is heated, the material is sheared, melted, plasticized, and mixed, and the molten material is extruded from the die of the machine head. It changes from high pressure to normal pressure when it is out, so that the gas dissolved in the material expands to complete the foaming.
- the most prominent feature of this molding method is continuous production, and different types of products can be produced by changing the head.
- Polyurethane rigid foam is a low-density microporous material with a closed-cell structure. It has the advantages of light weight, high specific strength, low thermal conductivity, low water absorption, and convenient construction and operation. It can be changed by changing the material composition, formula ratio, Synthetic conditions and methods to prepare foam materials with different hardness, chemical resistance and mechanical strength. Many physical properties of polyurethane foam materials depend on its cell structure. For rigid foam, closed-cell structure is appropriate for the cells.
- a frame for solar photovoltaic modules provided by the present invention includes a closed cavity 1; an installation notch for installing photovoltaic modules is provided above the closed cavity;
- a filling structure is provided in the closed cavity
- the frame is cold-formed by using steel plate or metal alloy plate as the base material, and the outer surface of the frame is provided with a corrosion-resistant metal coating, or is protected by brushing paint; or,
- the frame is extruded and formed by using aluminum alloy or magnesium alloy as a base material, and the surface of the aluminum alloy or magnesium alloy is oxidized or protected by brushing paint.
- closed cavity described in the present invention is not strictly “closed”, that is, the cavity is as closed as possible.
- the solar photovoltaic module frame provided by the present invention is suitable for single-sided modules and double-sided modules.
- the main structure of the module frame is made by selecting thin steel plates and adopting the process of cold-rolling forming, thereby greatly increasing the combined frame of the module This is because the strength of steel can reach more than three times the strength of aluminum, which fundamentally solves the problem of the strength of the module frame; and furthermore, a foam with high strength and good adhesion is set in the cavity of the module frame. Material, so that the foamed material and the steel component frame bear the force together, thereby further enhancing the yield strength of the component frame.
- the steel sheet is used in the present invention, the steel sheet is cold-rolled into a module frame with a cavity, and at the same time, a foaming material is arranged in the cavity, which can greatly increase the strength of the module frame. Therefore, the present invention There is no need to set the height of the module frame higher to accommodate large-size photovoltaic modules, so that the thickness and weight of the module frame can be effectively reduced.
- the height of the frame in the present invention is about 25mm.
- the frame of the present invention can be used for larger-specification modules without increasing The height of the border. Therefore, compared with the current module frame with a height of 45 mm, the module frame of the present invention can reduce the transportation cost by about 44%, and the storage space can save 44%. Its 4-point fixed installation method can save 50% of the number of press blocks.
- the present invention creatively uses the very light special effect of foaming materials to foam in the bent steel forming frame to form an integral frame with a honeycomb structure. Ensure the strength of the component frame without affecting the weight of the component frame.
- the extension length of the bottom wall is set to be greater than the extension length of the upper wall and the lower wall, so as to connect the integral frame with the purlin of the photovoltaic support, so that the module and the purlin can be directly connected instead of using the traditional pressing block to connect the purlin.
- the components are connected with the purlins of the photovoltaic support, saving installation materials and installation labor costs.
- the foaming material can be made of organic or inorganic materials, preferably rigid polyurethane foam or unsaturated polyester plastic.
- the unsaturated polyester plastic includes two components A and B, and the A component includes unsaturated polyester. Resin, thickener, initiator, and filler.
- the B component is glass fiber grit or glass fiber mat.
- the polyurethane foam in the present invention referred to as polyurethane rigid foam
- polyurethane rigid foam has excellent properties such as light weight, high strength, good dimensional stability, and strong adhesion. It is resistant to metals such as steel, aluminum, stainless steel, wood, concrete, and asphalt. Most plastic materials have good bonding strength.
- the closed cell rate of rigid polyurethane is more than 95%, it is a hydrophobic material, so that the module frame in this application has moisture-proof and water-proof properties; furthermore, because polyurethane is a difficult-to-use flame retardant after adding a flame retardant.
- the flammable self-extinguishing material has a softening point of more than 250 degrees Celsius, so that the frame of the module in this application has fire-retardant, flame-retardant, and high-temperature resistance performance.
- the component frame in the present application has strong resistance to deformation, is not easy to crack, and has a stable and safe finish.
- the left frame 111 of the closed cavity 11 extends upward to form a vertical frame 12, and the top of the vertical frame 12 extends to the right to form a top frame 13;
- the lower frame 112 of the closed cavity 11 extends to the right to form a bottom frame 15;
- the vertical frame 12, the top frame 13, and the upper frame 113 of the cavity 11 form the installation slot 14 for installing the photovoltaic module 8.
- the top frame 211 of the closed cavity 21 extends to the right to form a lower frame 26, the lower frame 26 extends upwards to form a vertical frame 22, and the vertical frame 22 extends to the left.
- the lower frame 212 of the closed cavity 21 extends to the right to form a bottom frame 25;
- the bottom frame 25, the vertical frame 22, the top frame 23, and the upper frame 213 of the cavity 21 form the installation slot 24 for installing the photovoltaic module 8.
- the steel sheet for coiling can also preferably use the highly corrosion-resistant coated steel sheet "SuperDyma” developed by Nippon Steel, or the aluminum-magnesium-zinc steel sheet of Pohang Steel, Korea.
- Nippon Steel SuperDyma As an example.
- Its coating composition is mainly zinc, a new type of corrosion-resistant coated steel sheet composed of 11% aluminum, 3% magnesium and a trace amount of silicon. It has good rust resistance and processing properties, such as flat surface. It has good rust prevention at the end and the bending part and the stretched part are not easy to rust. There are few scratches on the surface of the processed part, and the weldability and paintability are also very good.
- the adoption of the latest anti-corrosion measures or the use of anti-corrosion finished steel can provide the steel with a service life of 30-50 years, thereby fundamentally solving the problem of corrosion and service life of the steel.
- the vertical frame 12, the top frame 13, and the bottom frame 15 are all rolled to form a double-layer structure.
- the vertical frame 12 and the top frame 13 are both rolled to form a double-layer structure .
- this embodiment takes into account the need to pass through the bottom frame 5 of the frame; the photovoltaic module and the overall frame are fixed on the purlin. Therefore, in this embodiment, the bottom frame 15 of the frame is set in a double-layer structure to increase the bottom frame 15. Strength of.
- the edge seam of the frame is rolled and occluded or welded to form a closed cavity.
- a filling structure is provided in the cavity of the frame.
- Foaming when the frame is rolled by a steel plate or a metal alloy sheet, or the frame is extruded by an aluminum alloy or magnesium alloy, a filling structure is provided in the cavity of the frame.
- the steel rolling process and the foaming process in this embodiment can be performed at the same time, that is, foaming while rolling is achieved, which cannot be achieved with the aluminum frame manufacturing process using the injection molding process.
- the production process of foaming while rolling is simple and easy to realize; and the foaming area can be controlled, and the foaming speed can be controlled at the same time, so as to control the production quality of the frame and the uniformity of foaming.
- a first connector 6 is provided at the inner connection of the long side and the short side of the frame.
- the first connector 6 is detachably fixed on the bottom wall 13.
- the connecting piece 6 is used for the connection between the long side and the short side on the same frame.
- this embodiment only uses the installation method of the first connector in the embodiment structure corresponding to FIG. 1 as an example for description, and the installation method of the first connector in the embodiment structure corresponding to FIG. 2 corresponds to FIG. 1
- the installation method of the first connecting member in the structure of the embodiment is completely the same, and the description is not repeated in this embodiment.
- a second connector 7 is provided at the outer connection of the long side and the short side of the frame, and the second connector 7 is used for the connection between adjacent frames.
- the connecting pieces are inserted into the long and short sides of the assembly respectively, and the connection is completed by the friction formed by the extrusion or the alveolar engagement on the structure, or the connection is made by arranging structural glue.
- this embodiment only uses the installation method of the first connector in the embodiment structure corresponding to FIG. 1 as an example for description, and the installation method of the first connector in the embodiment structure corresponding to FIG. 2 corresponds to FIG. 1
- the installation method of the first connecting member in the structure of the embodiment is completely the same, and the description is not repeated in this embodiment.
- the outer joints of the long side and the short side of the frame may be connected by a welding process to connect the long side and the short side as a whole.
- the welding methods in this embodiment include resistance welding, laser welding and cold welding.
- the implementation of the present invention adds force analysis from the software simulation calculation:
- the stress analysis of the component frame under unfavorable wind loads is carried out.
- the selected steel material is Q345, the components are fixed according to the installation method and the constraints are set accordingly (that is, the long side is fixed at two points), and the load is 2400Pa (which can meet the basic wind pressure calculation of not greater than 0.85KN/m2) and the pressure load is transferred to the module frame On the long side, the calculated stress and deformation results are shown in Figure 8.
- the thickness of the surface sheet is 0.6mm, and the interior is filled with foam materials such as polyurethane.
- the inner filling foam material can work together with the surface sheet.
- the external environment temperature (-20° ⁇ 30°) has no effect on the bending and compressive strength of the internal filling material.
- the surface sheet is made of Q345 steel.
- the inner filling polyurethane material ⁇ filling takes 30Mpa
- ⁇ is the yield strength of rolled steel, which can be 305Mpa;
- W1 is the section modulus of rolled steel, which is calculated and determined according to the actual section height and width;
- ⁇ is the strength reduction coefficient of the material, which varies according to the filling material, and the value is 0.5 ⁇ 0.9;
- ⁇ is the yield strength of the filling material, such as polyurethane material can take a value of 30Mpa.
- W2 is the section modulus of the filling material, which is calculated and determined according to the actual section height and width.
- the foamed filling material and the rolled steel are tightly combined to bear the force.
- the filling material in the rolled steel can provide about 10-15% of the bearing capacity according to the overall cross-sectional form, cavity volume, filling material, etc., finite element
- the simulation value agrees with the theoretical calculation value.
- the foamed material provides strength and stability for the overall frame, and reduces the height of the frame structure.
- the frame height of the 72 pieces of modules commonly used in the market is preferred.
- the frame height in this example can be within 28mm, compared with the conventional height of 35-45mm aluminum frame There is a big advantage.
- the present invention also provides a photovoltaic module.
- the photovoltaic module includes the above-mentioned frame for solar photovoltaic modules. Since the improvement is only on the frame, the present invention does not describe other structures of the photovoltaic module in detail, and all existing structures can be used. Technical structure.
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- Photovoltaic Devices (AREA)
Abstract
Provided are a frame for solar photovoltaic module and a photovoltaic module. The frame comprises a closed cavity (11), a mounting notch (14) for mounting a photovoltaic module (8) is arranged in the upper portion of the closed cavity (11); the frame uses cold bending of a metal sheet and metal extrusion to form the closed cavity (11) and a mounting structure, the closed cavity (11) is filled with the foaming material. The steel thin sheet is selected, and a main body structure of the frame of the module is manufactured using the cold bending and rolling forming process, so that the strength of the frame of the module is greatly improved, further, the cellular structure foaming material with high strength and good adhesion is arranged in the cavity of the the frame of the module, so that the foaming material and the steel module frame are stressed together, and the yield strength of the module combined frame is further enhanced. Compared with the increase of the quality of the frame by the foaming material, the effect of filling the cavity with the foaming material on the increase of the structural strength is more obvious.
Description
本发明涉及光伏组件技术领域,具体涉及一种太阳能光伏组件用边框及光伏组件。The invention relates to the technical field of photovoltaic modules, in particular to a frame for solar photovoltaic modules and photovoltaic modules.
一般光伏组件的周边安装有边框,太阳能电池层压件的边缘容纳在边框的槽口内,光伏组件通过其边框安装在支架上。光伏组件的边框起到了增强组件强度和密封组件边缘的作用。Generally, a frame is installed around the periphery of the photovoltaic module, the edge of the solar cell laminate is accommodated in the notch of the frame, and the photovoltaic module is installed on the support through the frame. The frame of the photovoltaic module plays a role in enhancing the strength of the module and sealing the edge of the module.
2012年以前,存在100-156mm等多种形状、尺寸的硅片,且行业标准不统一;2015年由五个主要厂家统一标准为156.75毫米(即M2硅片)到2018年行业主流单晶硅片已全部采用156.75毫米尺寸设计,当前市占率在85%;2019年6月,市场上推出的166毫米硅片,将硅片尺寸推到了当前产业链生产线的冗余极限;2019年8月,市场上又推出210毫米的大硅片,将大尺寸推到了极致,大尺寸的硅片必然会带来大尺寸的组件,因此设计和生产适应最新硅片和组件尺寸的新式边框显得特别重要。Before 2012, there were silicon wafers of various shapes and sizes such as 100-156mm, and the industry standards were not uniform; in 2015, the five major manufacturers unified the standard to 156.75 mm (ie M2 wafers) to the mainstream monocrystalline silicon in the industry in 2018 The wafers have all been designed with a size of 156.75 mm, and the current market share is 85%; in June 2019, the 166 mm wafers launched on the market pushed the wafer size to the redundancy limit of the current industrial chain production line; August 2019 , The market has launched a 210mm large silicon wafer, pushing the large size to the extreme. Large-size silicon wafers will inevitably bring large-size components. Therefore, it is particularly important to design and produce new frames that adapt to the latest silicon wafers and component sizes. .
并且,随着技术的发展,光伏玻璃的厚度有逐渐减薄的趋势,厚度已从3.2mm变化到2.5mm,甚至2.0mm。根据不同组件类型,可分为单玻组件和双玻组件,其中单玻组件选用玻璃厚度从3.2mm变化到2.8mm;双玻组件的玻璃厚度从2.5+2.5mm向2.0+2.0mm变化,同时组件厚度的变化也要求边框设计要及时跟进最新组件厚度的设计要求。Moreover, with the development of technology, the thickness of photovoltaic glass has a tendency to gradually become thinner, and the thickness has changed from 3.2mm to 2.5mm, or even 2.0mm. According to different module types, it can be divided into single glass module and double glass module. The glass thickness of single glass module varies from 3.2mm to 2.8mm; the glass thickness of double glass module varies from 2.5+2.5mm to 2.0+2.0mm. Changes in component thickness also require frame design to follow up with the latest component thickness design requirements.
现有光伏组件的边框多使用铝合金材料制成,其存在以下缺点:The frames of existing photovoltaic modules are mostly made of aluminum alloy materials, which have the following disadvantages:
1.现有铝制边框的强度受到限制。纵观光伏组件发展的历史,组件尺寸从 250*175*25mm变化到现在的1950*995*45mm,组件尺寸增大了很多,以后还将朝着更大尺寸发展。而组件尺寸的变大,使得铝制光伏组件边框的尺寸朝着边框截面更大、厚度更厚的方向发展,这一现象的本质原因是铝材质本身强度低,在组件尺寸变大的情况下,使用铝合金材料制作型材,组件边框截面就需采用截面更大、厚度更厚的结构来增强,而截面更大、厚度更厚的结构将会增加使用成本。2.现有铝制边框运输和仓储成本高。随着光伏组件高度的增加,即组件高度从25mm变化到现在的40mm乃至更大,光伏组件的包装成本和运输成本都随之增加,光伏组件的仓储空间也受到了限制。1. The strength of the existing aluminum frame is limited. Throughout the history of the development of photovoltaic modules, the size of the module has changed from 250*175*25mm to the current 1950*995*45mm. The size of the module has increased a lot, and it will develop towards larger sizes in the future. As the module size becomes larger, the frame size of the aluminum photovoltaic module develops toward a larger frame cross section and thicker thickness. The essential reason for this phenomenon is the low strength of the aluminum material itself. When the module size becomes larger , The use of aluminum alloy materials to make the profile, the module frame section needs to be reinforced with a larger section and thicker structure, and a larger section and thicker structure will increase the use cost. 2. The existing aluminum frame has high transportation and storage costs. As the height of photovoltaic modules increases, that is, the module height changes from 25mm to the current 40mm or even larger, the packaging costs and transportation costs of photovoltaic modules have also increased, and the storage space of photovoltaic modules has also been restricted.
3.接线盒限高度值减少。接线盒是光伏组件的重要组成部分,其内部含有二极管或者功率开关等重要元器件,组件边框在设计时必须考虑接线盒的影响——组件边框下方的设计高度通常要高于接线盒的高度。传统技术的接线盒厚度有20mm,随着技术的发展,现在已经做到18mm,可见,接线盒的高度并不影响组件边框的高度,采用半导体芯片直接与接线盒铜排集成封装则可以使接线盒朝着更薄的方向发展。但铝边框因为材质的屈服强度低的原因,其高度不能有效降低,不利于减少边框耗材和组件成本。3. The height limit of the junction box is reduced. The junction box is an important part of the photovoltaic module. It contains important components such as diodes or power switches. The design of the module frame must consider the influence of the junction box-the design height under the module frame is usually higher than the height of the junction box. The thickness of the junction box of the traditional technology is 20mm. With the development of technology, it has now reached 18mm. It can be seen that the height of the junction box does not affect the height of the module frame. The semiconductor chip is directly integrated with the junction box copper bar to make the wiring. The box is moving in a thinner direction. However, the height of the aluminum frame cannot be effectively reduced due to the low yield strength of the material, which is not conducive to reducing the cost of frame consumables and components.
综上,采用强度更高的材料制作厚度更薄的边框是组件封装技术的发展方向。In summary, the use of higher-strength materials to make thinner bezels is the development direction of component packaging technology.
发明内容Summary of the invention
本发明的目的在于克服现有技术的不足,提供一种太阳能光伏组件用边框及光伏组件。The purpose of the present invention is to overcome the shortcomings of the prior art and provide a frame for solar photovoltaic modules and photovoltaic modules.
本发明提供的一种太阳能光伏组件用边框,其技术方案包括:The present invention provides a frame for solar photovoltaic modules, and its technical solution includes:
包括闭合腔体,所述闭合腔体的上方设置有安装光伏组件的安装槽口;其特征在于,It includes a closed cavity, and an installation notch for installing photovoltaic modules is arranged above the closed cavity; and is characterized in that:
所述边框采用钢制薄板冷弯卷制成型或合金材料挤压成型而成;The frame is formed by cold-rolled steel sheet or extrusion formed by alloy material;
所述闭合腔体内设置有填充结构;A filling structure is provided in the closed cavity;
所述边框选用钢板或金属合金板作为基材冷弯成型,其外表面设置有耐腐蚀的金属涂层,或采用涂刷涂料保护;或,The frame is cold-formed by using steel plate or metal alloy plate as the base material, and the outer surface of the frame is provided with a corrosion-resistant metal coating, or protected by brushing paint; or,
所述边框选用铝合金或镁合金作为基材挤压成型,所述铝合金、镁合金的表面进行氧化处理或采用涂刷涂料保护。The frame is extruded and formed by using aluminum alloy or magnesium alloy as a base material, and the surface of the aluminum alloy or magnesium alloy is oxidized or protected by brushing paint.
本发明提供的一种太阳能光伏组件用边框,还包括如下附属技术方案:The frame for solar photovoltaic modules provided by the present invention further includes the following subsidiary technical solutions:
其中,:所述闭合腔体的左框向上延伸形成竖边框,所述竖边框的顶部向右延伸形成顶边框;Wherein: the left frame of the closed cavity extends upward to form a vertical frame, and the top of the vertical frame extends to the right to form a top frame;
所述闭合腔体的下框向右延伸形成底边框;The lower frame of the closed cavity extends to the right to form a bottom frame;
所述竖边框、顶边框、以及腔体的上框形成所述用于安装光伏组件的安装槽口。The vertical frame, the top frame, and the upper frame of the cavity form the installation slot for installing the photovoltaic module.
其中,所述闭合腔体的顶框向右延伸形成下边框,所述下边框向上延伸形成竖边框,所述竖边框向左延伸形成顶边框;Wherein, the top frame of the closed cavity extends rightward to form a lower frame, the lower frame extends upward to form a vertical frame, and the vertical frame extends to the left to form a top frame;
所述闭合腔体的下框向右延伸形成底边框;The lower frame of the closed cavity extends to the right to form a bottom frame;
所述底边框、竖边框、顶边框、以及腔体的上框形成所述用于安装光伏组件的安装槽口。The bottom frame, the vertical frame, the top frame, and the upper frame of the cavity form the installation slot for installing the photovoltaic module.
其中,所述钢质或者硬质铝合金薄板表面镀敷耐腐蚀镀层、氧化镀层或者涂料涂层,所述金属薄板的厚度为0.3-1.2mm,优选0.4-0.6mm。Wherein, the surface of the steel or hard aluminum alloy sheet is plated with a corrosion-resistant coating, an oxidation coating or a paint coating, and the thickness of the metal sheet is 0.3-1.2 mm, preferably 0.4-0.6 mm.
其中,所述发泡材料采用有机发泡材料或无机发泡材料制作。Wherein, the foaming material is made of organic foaming material or inorganic foaming material.
其中,所述发泡材料为硬质聚氨酯泡沫塑料或不饱和聚酯塑料,所述不饱和聚酯塑料包括A和B两种组分,A组分包括不饱和聚酯树脂、增稠剂、引发剂、以及填料,B组分为玻璃纤维粗砂或玻璃纤维毡。Wherein, the foaming material is a rigid polyurethane foam plastic or an unsaturated polyester plastic, the unsaturated polyester plastic includes two components A and B, and the A component includes an unsaturated polyester resin, a thickener, Initiator and filler, component B is glass fiber grit or glass fiber mat.
其中,所述竖边框、顶边框、以及底边框均卷制形成至少两层结构。Wherein, the vertical frame, the top frame, and the bottom frame are all rolled to form at least a two-layer structure.
其中,所述边框的边缝处进行翻卷咬合、或焊接处理,以形成闭合腔体。Wherein, the edge seam of the frame is rolled and occluded or welded to form a closed cavity.
其中,在采用钢板或金属合金板卷制所述边框,或采用铝合金或镁合金挤压成型所述边框的过程中,在所述边框的腔体中设置填充结构进行发泡。Wherein, in the process of rolling the frame with a steel plate or a metal alloy plate, or extruding the frame with an aluminum alloy or magnesium alloy, a filling structure is provided in the cavity of the frame for foaming.
其中,所述边框的长边与短边的内连接处设置有第一连接件,所述第一连 接件可拆卸地固定于所述底壁上,所述第一连接件用于同一个边框上的长边和短边之间的连接。Wherein, the inner connection of the long side and the short side of the frame is provided with a first connecting piece, the first connecting piece is detachably fixed on the bottom wall, and the first connecting piece is used for the same frame The connection between the long side and the short side on the top.
其中,所述边框的长边与短边的外连接处设置有第二连接件,所述第二连接件用于相邻边框之间的连接。Wherein, a second connecting piece is provided at the outer connection of the long side and the short side of the frame, and the second connecting piece is used for the connection between adjacent frames.
其中,所述边框的长边与短边的外侧采用焊接连接,所述焊接可选用电阻焊、激光焊或冷焊焊接。Wherein, the outer sides of the long side and the short side of the frame are connected by welding, and the welding can be resistance welding, laser welding or cold welding.
本发明还提供了一种光伏组件,所述光伏组件包含上述所述的一种太阳能光伏组件用边框。The present invention also provides a photovoltaic module, which includes the aforementioned frame for a solar photovoltaic module.
本发明的实施包括以下技术效果:The implementation of the present invention includes the following technical effects:
本发明提供的太阳能光伏组件用边框适用于单面组件和双面组件,通过选用钢板或金属合金板,并采用冷弯卷制成型的工艺制作组件边框的主体结构,从而极大地增加了组件边框的强度,这是由于钢材的强度可以达到铝材强度的三倍以上,从而从根本上解决了组件边框强度的问题;并进一步在组件边框的腔体内设置强度高、粘接性好的发泡材料、以使该发泡材料与钢制组件边框共同受力,从而进一步增强组件边框的屈服强度。可见,由于本发明中采用钢制薄板,将钢制薄板冷弯卷制成型具有腔体的组件边框,同时在腔体内设置发泡材料,能够极大地增加组件边框的强度,因此,本发明不需要将组件边框的高度设置的更高,以适应大尺寸的光伏组件,从而可以有效降低组件边框的厚度和重量。选用铝合金或镁合金作为基材挤压成型的边框结构也可以起到明显的增强作用。The solar photovoltaic module frame provided by the present invention is suitable for single-sided modules and double-sided modules. The main structure of the module frame is made by selecting steel plates or metal alloy plates and adopting the process of cold-rolling forming, thereby greatly increasing the number of modules. The strength of the frame, this is because the strength of the steel can reach more than three times the strength of the aluminum material, which fundamentally solves the problem of the strength of the module frame; and further provides a high-strength and good adhesiveness in the cavity of the module frame. Foam material to make the foam material and the steel component frame work together to further enhance the yield strength of the component frame. It can be seen that because the steel sheet is used in the present invention, the steel sheet is cold-rolled into a module frame with a cavity, and at the same time, a foaming material is arranged in the cavity, which can greatly increase the strength of the module frame. Therefore, the present invention There is no need to set the height of the module frame higher to accommodate large-size photovoltaic modules, so that the thickness and weight of the module frame can be effectively reduced. The frame structure extruded by using aluminum alloy or magnesium alloy as the base material can also play a significant role in reinforcement.
具体地,在目前的72片大组件中,本发明中的边框高度约25mm,通过在腔体内填充材料以增加强度,使本发明中的组件边框能够胜任规格更大的组件,而不会增加边框的高度。因此,本发明中组件边框相较于目前45mm高度的组件边框,其运输成本能够降低约44%,仓储空间能够节约44%,其4点固定的安装方式使得压块数量能够节约50%。Specifically, in the current 72 large modules, the height of the frame in the present invention is about 25mm. By filling the cavity with materials to increase the strength, the frame of the present invention can be used for larger-specification modules without increasing The height of the border. Therefore, compared with the current module frame with a height of 45 mm, the module frame of the present invention can reduce the transportation cost by about 44%, and the storage space can save 44%. Its 4-point fixed installation method can save 50% of the number of press blocks.
并且,考虑到边框材料从铝合金材质变成钢材时,其强度虽然增加了,但 选用较厚的钢材,其重量也会大大增加,特别是钢材没有铝合金那样的挤出成材条件,折弯的钢材焊接成整体的加工难度和工艺成本较高,本发明创造性地利用发泡材料非常轻的特效,在折弯的钢材成型框里发泡,使之形成蜂窝结构的整体式框架,既能保证组件边框的强度,又不影响组件边框的重量。Moreover, considering that when the frame material is changed from aluminum alloy to steel, its strength increases, but thicker steel is used, and its weight will also increase greatly. Especially steel does not have the extrusion conditions of aluminum alloy, and the bending The processing difficulty and process cost of welding the steel into a whole are relatively high. The present invention creatively uses the very light special effect of foaming materials to foam in the bent steel forming frame to form an integral frame with a honeycomb structure. Ensure the strength of the component frame without affecting the weight of the component frame.
本发明通过将底壁的延伸长度设置成大于上壁与下壁的延伸长度,以用于将整体边框与光伏支架檩条连接,从而可以将组件与檩条直接连接,而不是采用传统的压块将组件与光伏支架檩条连接,节省了安装材料和安装人力成本。In the present invention, the extension length of the bottom wall is set to be greater than the extension length of the upper wall and the lower wall, so as to connect the integral frame with the purlin of the photovoltaic support, so that the module and the purlin can be directly connected instead of using the traditional pressing block to connect the purlin. The components are connected with the purlins of the photovoltaic support, saving installation materials and installation labor costs.
图1为本发明的一个实施例的太阳能光伏组件用边框的结构示意图。Fig. 1 is a schematic structural diagram of a frame for a solar photovoltaic module according to an embodiment of the present invention.
图2为本发明的一个实施例的太阳能光伏组件用边框的结构示意图。Fig. 2 is a schematic structural diagram of a frame for a solar photovoltaic module according to an embodiment of the present invention.
图3为本发明的第一连接件的结构示意图。Fig. 3 is a schematic diagram of the structure of the first connecting member of the present invention.
图4为本发明的第一连接件的安装示意图。Fig. 4 is a schematic diagram of the installation of the first connector of the present invention.
图5为本发明的第二连接件的结构示意图。Fig. 5 is a schematic diagram of the structure of the second connecting member of the present invention.
图6为本发明的第二连接件的安装示意图。Fig. 6 is a schematic diagram of the installation of the second connector of the present invention.
图7为本发明的太阳能光伏组件用边框的长边和短边连接示意图。Fig. 7 is a schematic diagram of the connection of the long side and the short side of the frame for the solar photovoltaic module of the present invention.
图8为有限元分析图。Figure 8 is a finite element analysis diagram.
图8为计算截面的示意图。Fig. 8 is a schematic diagram of the calculated cross section.
图10为有限元分析图。Figure 10 is a finite element analysis diagram.
这里将详细地对示例性实施例进行说明,其示例表示在附图中。下面的描述涉及附图时,除非另有表示,不同附图中的相同数字表示相同或相似的要素。以下示例性实施例中所描述的实施方式并不代表与本发明相一致的所有实施方式。相反,它们仅是与如所附权利要求书中所详述的、本发明的一些方面相一致的装置和方法的例子。The exemplary embodiments will be described in detail here, and examples thereof are shown in the accompanying drawings. When the following description refers to the drawings, unless otherwise indicated, the same numbers in different drawings indicate the same or similar elements. The implementation manners described in the following exemplary embodiments do not represent all implementation manners consistent with the present invention. On the contrary, they are merely examples of devices and methods consistent with some aspects of the present invention as detailed in the appended claims.
一般地,卷板是利用卷板机对板料进行连续三点弯曲的过程。设备在进行 卷板时将板料放在上、下工作辊之间。上辊垂直升降,两下辊做旋转运动且相对于上辊轴心面水平移动。上辊下降时,板材在上下工作辊之间发生塑性变形而弯曲。下辊连续旋转通过板与辊之间的摩擦力带动钢板进、退,完成卷制,整个过程中还包含了如预弯、对中、卷圆、矫圆等操作。Generally, plate rolling is a process of continuous three-point bending of the sheet metal using a plate rolling machine. The equipment puts the sheet between the upper and lower work rolls during the rolling. The upper roller is raised and lowered vertically, and the two lower rollers rotate and move horizontally relative to the axis of the upper roller. When the upper roll descends, the plate is plastically deformed and bent between the upper and lower work rolls. The continuous rotation of the bottom roller drives the steel plate to advance and retreat through the friction between the plate and the roller to complete the coiling. The entire process also includes operations such as pre-bending, centering, rounding, and rounding.
化工领域发泡材料种类很多,按硬度分类可分为软质、硬质和半硬质,按密度分类分为低发泡泡沫材料、中发泡泡沫材料和高发泡泡沫料等。常见的发泡工艺方法如间歇发泡法、模压发泡法、挤出发泡法等,优选的采用挤出发泡法。挤出发泡法是将含发泡剂的塑料原料加入挤出机中,经螺杆旋转和机筒外的加热,物料被剪切、熔融、塑化、混合,熔融物料从机头模口挤出时由高压变为常压,使溶于物料内的气体膨胀而完成发泡。这种成型方法最突出的特点是连续化生产,通过更换机头就可以生产不同类型的产品。There are many types of foaming materials in the chemical industry. According to the hardness, they can be divided into soft, rigid and semi-rigid. According to the density, they can be divided into low-foaming foam, medium-foaming foam and high-foaming foam. Common foaming process methods such as intermittent foaming method, molded foaming method, extrusion foaming method, etc., extrusion foaming method is preferably used. The extrusion foaming method is to add the plastic material containing the foaming agent into the extruder, after the screw is rotated and the barrel is heated, the material is sheared, melted, plasticized, and mixed, and the molten material is extruded from the die of the machine head. It changes from high pressure to normal pressure when it is out, so that the gas dissolved in the material expands to complete the foaming. The most prominent feature of this molding method is continuous production, and different types of products can be produced by changing the head.
比较优选的聚氨酯PU发泡填缝材料已广泛应用于家装门窗等领域。聚氨酯硬质泡沫是一种具有闭孔结构的低密度微孔材料,具有质轻、比强度高、导热系数小、吸水率低、施工操作方便的优点,可以通过改变材料的组成、配方比例、合成条件方法等来制得不同软硬度、耐化学性以及机械强度的泡沫材料。聚氨酯发泡材料的许多物理特性都取决于他的泡孔结构,对硬质泡沫来说,泡孔以闭孔结构为宜。The more preferred polyurethane PU foamed joint fillers have been widely used in home improvement doors and windows and other fields. Polyurethane rigid foam is a low-density microporous material with a closed-cell structure. It has the advantages of light weight, high specific strength, low thermal conductivity, low water absorption, and convenient construction and operation. It can be changed by changing the material composition, formula ratio, Synthetic conditions and methods to prepare foam materials with different hardness, chemical resistance and mechanical strength. Many physical properties of polyurethane foam materials depend on its cell structure. For rigid foam, closed-cell structure is appropriate for the cells.
如图1-3、5所示,本发明提供的一种太阳能光伏组件用边框,包括闭合腔体1;所述闭合腔体的上方设置有安装光伏组件的安装槽口;As shown in Figures 1-3 and 5, a frame for solar photovoltaic modules provided by the present invention includes a closed cavity 1; an installation notch for installing photovoltaic modules is provided above the closed cavity;
所述闭合腔体内设置有填充结构;A filling structure is provided in the closed cavity;
所述边框选用钢板或金属合金板作为基材冷弯成型,其外表面设置有耐腐蚀的金属涂层,或采用涂刷涂料保护;或,The frame is cold-formed by using steel plate or metal alloy plate as the base material, and the outer surface of the frame is provided with a corrosion-resistant metal coating, or is protected by brushing paint; or,
所述边框选用铝合金或镁合金作为基材挤压成型,所述铝合金、镁合金的表面进行氧化处理或采用涂刷涂料保护。The frame is extruded and formed by using aluminum alloy or magnesium alloy as a base material, and the surface of the aluminum alloy or magnesium alloy is oxidized or protected by brushing paint.
需要说明的是,本发明中所述的闭合腔体并不是严格意义上的“闭合”,即,该腔体是尽可能闭合的腔体。It should be noted that the closed cavity described in the present invention is not strictly "closed", that is, the cavity is as closed as possible.
本发明提供的太阳能光伏组件用边框适用于单面组件和双面组件,通过选用钢制薄板,并采用冷弯卷制成型的工艺制作组件边框的主体结构,从而极大地增加了组件组合边框的强度,这是由于钢材的强度可以达到铝材强度的三倍以上,从而从根本上解决了组件边框强度的问题;并进一步在组件边框的腔体内设置强度高、粘接性好的发泡材料、以使该发泡材料与钢制组件边框共同受力,从而进一步增强组件边框的屈服强度。可见,由于本发明中采用钢制薄板,将钢制薄板冷弯卷制成型具有腔体的组件边框,同时在腔体内设置发泡材料,能够极大地增加组件边框的强度,因此,本发明不需要将组件边框的高度设置的更高,以适应大尺寸的光伏组件,从而可以有效降低组件边框的厚度和重量。The solar photovoltaic module frame provided by the present invention is suitable for single-sided modules and double-sided modules. The main structure of the module frame is made by selecting thin steel plates and adopting the process of cold-rolling forming, thereby greatly increasing the combined frame of the module This is because the strength of steel can reach more than three times the strength of aluminum, which fundamentally solves the problem of the strength of the module frame; and furthermore, a foam with high strength and good adhesion is set in the cavity of the module frame. Material, so that the foamed material and the steel component frame bear the force together, thereby further enhancing the yield strength of the component frame. It can be seen that because the steel sheet is used in the present invention, the steel sheet is cold-rolled into a module frame with a cavity, and at the same time, a foaming material is arranged in the cavity, which can greatly increase the strength of the module frame. Therefore, the present invention There is no need to set the height of the module frame higher to accommodate large-size photovoltaic modules, so that the thickness and weight of the module frame can be effectively reduced.
具体地,在目前的72片大组件中,本发明中的边框高度约25mm,通过在腔体内填充材料以增加强度,使本发明中的组件边框能够胜任规格更大的组件,而不会增加边框的高度。因此,本发明中组件边框相较于目前45mm高度的组件边框,其运输成本能够降低约44%,仓储空间能够节约44%,其4点固定的安装方式使得压块数量能够节约50%。Specifically, in the current 72 large modules, the height of the frame in the present invention is about 25mm. By filling the cavity with materials to increase the strength, the frame of the present invention can be used for larger-specification modules without increasing The height of the border. Therefore, compared with the current module frame with a height of 45 mm, the module frame of the present invention can reduce the transportation cost by about 44%, and the storage space can save 44%. Its 4-point fixed installation method can save 50% of the number of press blocks.
并且,考虑到边框材料从铝合金材质变成钢材时,其强度虽然增加了,但选用较厚的钢材,其重量也会大大增加,特别是钢材没有铝合金那样的挤出成材条件,折弯的钢材焊接成整体的加工难度和工艺成本较高,本发明创造性地利用发泡材料非常轻的特效,在折弯的钢材成型框里发泡,使之形成蜂窝结构的整体式框架,既能保证组件边框的强度,又不影响组件边框的重量。Moreover, considering that when the frame material is changed from aluminum alloy to steel, its strength increases, but thicker steel is used, and its weight will also increase greatly. Especially steel does not have the extrusion conditions of aluminum alloy, and the bending The processing difficulty and process cost of welding the steel into a whole are relatively high. The present invention creatively uses the very light special effect of foaming materials to foam in the bent steel forming frame to form an integral frame with a honeycomb structure. Ensure the strength of the component frame without affecting the weight of the component frame.
本发明通过将底壁的延伸长度设置成大于上壁与下壁的延伸长度,以用于将整体边框与光伏支架檩条连接,从而可以将组件与檩条直接连接,而不是采用传统的压块将组件与光伏支架檩条连接,节省了安装材料和安装人力成本。In the present invention, the extension length of the bottom wall is set to be greater than the extension length of the upper wall and the lower wall, so as to connect the integral frame with the purlin of the photovoltaic support, so that the module and the purlin can be directly connected instead of using the traditional pressing block to connect the purlin. The components are connected with the purlins of the photovoltaic support, saving installation materials and installation labor costs.
其中,发泡材料可以采用有机材料或无机材料制作,优选硬质聚氨酯泡沫塑料或不饱和聚酯塑料制作,不饱和聚酯塑料包括A和B两种组分,A组分包括不饱和聚酯树脂、增稠剂、引发剂、以及填料,B组分为玻璃纤维粗砂或玻璃纤维毡。Among them, the foaming material can be made of organic or inorganic materials, preferably rigid polyurethane foam or unsaturated polyester plastic. The unsaturated polyester plastic includes two components A and B, and the A component includes unsaturated polyester. Resin, thickener, initiator, and filler. The B component is glass fiber grit or glass fiber mat.
具体地,本发明中的聚氨酯泡沫塑料,简称聚氨酯硬泡,具有重量轻、强度高等优良性能,且尺寸稳定性好,粘结力强,对钢、铝、不锈钢等金属,木材、混凝土、沥青等大多塑料材料具有良好的粘结强度。并且,由于硬质聚氨酯的闭孔率在95%以上,属于憎水性材料,从而使得本申请中的组件边框具有防潮、防水性能;再者,由于聚氨酯在添加阻燃剂后,是一种难燃的自熄性材料,它的软化点可达到250摄氏度以上,从而使得本申请中的组件边框具有防火,阻燃,耐高温性能。最后,本申请中的组件边框抗变形能力强,不易开裂,饰面稳定、安全。Specifically, the polyurethane foam in the present invention, referred to as polyurethane rigid foam, has excellent properties such as light weight, high strength, good dimensional stability, and strong adhesion. It is resistant to metals such as steel, aluminum, stainless steel, wood, concrete, and asphalt. Most plastic materials have good bonding strength. Moreover, since the closed cell rate of rigid polyurethane is more than 95%, it is a hydrophobic material, so that the module frame in this application has moisture-proof and water-proof properties; furthermore, because polyurethane is a difficult-to-use flame retardant after adding a flame retardant. The flammable self-extinguishing material has a softening point of more than 250 degrees Celsius, so that the frame of the module in this application has fire-retardant, flame-retardant, and high-temperature resistance performance. Finally, the component frame in the present application has strong resistance to deformation, is not easy to crack, and has a stable and safe finish.
如图1所示,在一个实施例中,所述闭合腔体11的左框111向上延伸形成竖边框12,所述竖边框12的顶部向右延伸形成顶边框13;As shown in FIG. 1, in one embodiment, the left frame 111 of the closed cavity 11 extends upward to form a vertical frame 12, and the top of the vertical frame 12 extends to the right to form a top frame 13;
所述闭合腔体11的下框112向右延伸形成底边框15;The lower frame 112 of the closed cavity 11 extends to the right to form a bottom frame 15;
所述竖边框12、顶边框13、以及腔体11的上框113形成所述用于安装光伏组件8的安装槽口14。The vertical frame 12, the top frame 13, and the upper frame 113 of the cavity 11 form the installation slot 14 for installing the photovoltaic module 8.
如图2所示,在一个实施例中,所述闭合腔体21的顶框211向右延伸形成下边框26,所述下边框26向上延伸形成竖边框22,所述竖边框22向左延伸形成顶边框23;As shown in FIG. 2, in one embodiment, the top frame 211 of the closed cavity 21 extends to the right to form a lower frame 26, the lower frame 26 extends upwards to form a vertical frame 22, and the vertical frame 22 extends to the left. Form a top frame 23;
所述闭合腔体21的下框212向右延伸形成底边框25;The lower frame 212 of the closed cavity 21 extends to the right to form a bottom frame 25;
所述底边框25、竖边框22、顶边框23、以及腔体21的上框213形成所述用于安装光伏组件8的安装槽口24。The bottom frame 25, the vertical frame 22, the top frame 23, and the upper frame 213 of the cavity 21 form the installation slot 24 for installing the photovoltaic module 8.
另外,卷制用钢板也可优选地采用新日铁开发的高耐腐蚀性镀膜钢板“SuperDyma”,或者韩国浦项钢铁的铝镁锌钢板。以新日铁SuperDyma为例,其镀膜成分以锌为主,由11%的铝、3%的镁以及微量的硅构成的新型耐腐蚀性镀膜钢板,具有良好的防锈、加工性能,如平面和端部的的防锈均不错,弯曲成形部分、拉伸部分不易生锈,加工部表面少有伤痕,焊接性、油漆性也很好。In addition, the steel sheet for coiling can also preferably use the highly corrosion-resistant coated steel sheet "SuperDyma" developed by Nippon Steel, or the aluminum-magnesium-zinc steel sheet of Pohang Steel, Korea. Take Nippon Steel SuperDyma as an example. Its coating composition is mainly zinc, a new type of corrosion-resistant coated steel sheet composed of 11% aluminum, 3% magnesium and a trace amount of silicon. It has good rust resistance and processing properties, such as flat surface. It has good rust prevention at the end and the bending part and the stretched part are not easy to rust. There are few scratches on the surface of the processed part, and the weldability and paintability are also very good.
并且,采用最新防腐措施或采用防腐成品钢材,可以为钢材提供30-50年的使用寿命,从而从根本上解决钢材的易腐蚀和寿命问题。Moreover, the adoption of the latest anti-corrosion measures or the use of anti-corrosion finished steel can provide the steel with a service life of 30-50 years, thereby fundamentally solving the problem of corrosion and service life of the steel.
在一些优选的实施例中,如图1所示,所述竖边框12、顶边框13、以及底边框15均卷制形成双层结构。In some preferred embodiments, as shown in FIG. 1, the vertical frame 12, the top frame 13, and the bottom frame 15 are all rolled to form a double-layer structure.
本实施例考虑到光伏组件是放置在由竖边框12、顶边框13、以及腔体11的上框112形成安装槽口14,因此,将竖边框12与顶边框13均卷制形成双层结构,以防止放置在安装槽口14中的光伏组件将竖边框12与顶边框13挤压变形。同时,本实施例考虑到需要通过边框的1底边框5;将光伏组件、以及整体边框固定在檩条上、因此,本实施例将边框的底边框15设置成双层结构,以增加底边框15的强度。In this embodiment, considering that the photovoltaic module is placed in the mounting slot 14 formed by the vertical frame 12, the top frame 13, and the upper frame 112 of the cavity 11, the vertical frame 12 and the top frame 13 are both rolled to form a double-layer structure , To prevent the photovoltaic module placed in the installation slot 14 from squeezing and deforming the vertical frame 12 and the top frame 13. At the same time, this embodiment takes into account the need to pass through the bottom frame 5 of the frame; the photovoltaic module and the overall frame are fixed on the purlin. Therefore, in this embodiment, the bottom frame 15 of the frame is set in a double-layer structure to increase the bottom frame 15. Strength of.
在一些实施例中,如图1-3、5、6所示,边框的边缝处进行翻卷咬合、或焊接处理,以形成闭合腔体。In some embodiments, as shown in FIGS. 1-3, 5, and 6, the edge seam of the frame is rolled and occluded or welded to form a closed cavity.
在一些实施例中,在采用在采用钢板或金属合金板卷制所述边框,或采用铝合金或镁合金挤压成型所述边框的过程中,在所述边框的腔体中设置填充结构进行发泡。本实施例中的钢卷制工艺和发泡工艺可同时进行,即实现一边卷制一边发泡,这对于采用注塑工艺的铝边框制作工艺是实现不了的。此外,边卷制边发泡的制作工艺简单,容易实现;并且可以控制发泡区域,同时能控制发泡速度,从而控制边框的制作质量以及发泡的均匀性。In some embodiments, when the frame is rolled by a steel plate or a metal alloy sheet, or the frame is extruded by an aluminum alloy or magnesium alloy, a filling structure is provided in the cavity of the frame. Foaming. The steel rolling process and the foaming process in this embodiment can be performed at the same time, that is, foaming while rolling is achieved, which cannot be achieved with the aluminum frame manufacturing process using the injection molding process. In addition, the production process of foaming while rolling is simple and easy to realize; and the foaming area can be controlled, and the foaming speed can be controlled at the same time, so as to control the production quality of the frame and the uniformity of foaming.
在一些实施例中,如图3、4所示,边框的长边与短边的内连接处设置有第一连接件6,第一连接件6可拆卸地固定于底壁13上,第一连接件6用于同一个边框上的长边和短边之间的连接。In some embodiments, as shown in Figures 3 and 4, a first connector 6 is provided at the inner connection of the long side and the short side of the frame. The first connector 6 is detachably fixed on the bottom wall 13. The connecting piece 6 is used for the connection between the long side and the short side on the same frame.
为了便于说明,本实施例仅以图1对应的实施例结构中的第一连接件的安装方式为例进行说明,图2对应的实施例结构中的第一连接件的安装方式与图1对应的实施例结构中的第一连接件的安装方式完全相同,本实施例不再进行赘述。For ease of description, this embodiment only uses the installation method of the first connector in the embodiment structure corresponding to FIG. 1 as an example for description, and the installation method of the first connector in the embodiment structure corresponding to FIG. 2 corresponds to FIG. 1 The installation method of the first connecting member in the structure of the embodiment is completely the same, and the description is not repeated in this embodiment.
在一些实施例中,如图5、6所示,边框的长边与短边的外连接处设置有第二连接件7,第二连接件7用于相邻边框之间的连接。In some embodiments, as shown in Figs. 5 and 6, a second connector 7 is provided at the outer connection of the long side and the short side of the frame, and the second connector 7 is used for the connection between adjacent frames.
具体地,连接件分别插入到组件的长短边,靠挤压形成的摩擦力或结构上 的齿槽咬合完成连接、或通过设置结构胶进行连接。Specifically, the connecting pieces are inserted into the long and short sides of the assembly respectively, and the connection is completed by the friction formed by the extrusion or the alveolar engagement on the structure, or the connection is made by arranging structural glue.
为了便于说明,本实施例仅以图1对应的实施例结构中的第一连接件的安装方式为例进行说明,图2对应的实施例结构中的第一连接件的安装方式与图1对应的实施例结构中的第一连接件的安装方式完全相同,本实施例不再进行赘述。For ease of description, this embodiment only uses the installation method of the first connector in the embodiment structure corresponding to FIG. 1 as an example for description, and the installation method of the first connector in the embodiment structure corresponding to FIG. 2 corresponds to FIG. 1 The installation method of the first connecting member in the structure of the embodiment is completely the same, and the description is not repeated in this embodiment.
在一些实施例中,如图7所示,边框长边与短边的外侧连接处,可以通过焊接工艺进行连接,以将长边和短边连接为一个整体。In some embodiments, as shown in FIG. 7, the outer joints of the long side and the short side of the frame may be connected by a welding process to connect the long side and the short side as a whole.
其中,本实施例中的焊接方式包括电阻焊、激光焊和冷焊。Among them, the welding methods in this embodiment include resistance welding, laser welding and cold welding.
本发明的实施从软件模拟计算方面增加受力分析:The implementation of the present invention adds force analysis from the software simulation calculation:
基于有限元分析软件Solidworks对组件边框在不利风荷载等作用下进行应力分析。其中选用的钢材材质为Q345,根据安装方式固定组件并相应设置约束(即长边两点固定),荷载按2400Pa(可满足不大于0.85KN/m2的基本风压计算)压力加载传递至组件边框长边,计算应力及变形结果如图8所示。Based on the finite element analysis software Solidworks, the stress analysis of the component frame under unfavorable wind loads is carried out. The selected steel material is Q345, the components are fixed according to the installation method and the constraints are set accordingly (that is, the long side is fixed at two points), and the load is 2400Pa (which can meet the basic wind pressure calculation of not greater than 0.85KN/m2) and the pressure load is transferred to the module frame On the long side, the calculated stress and deformation results are shown in Figure 8.
从图7可以看出,组件在2400Pa荷载作用下,未考虑玻璃刚度的有利作用下,钢卷制边框计算可以满足强度要求,且变形很小。It can be seen from Figure 7 that under the action of the component under a load of 2400 Pa, without considering the advantageous effect of the glass stiffness, the steel coiled frame calculation can meet the strength requirements, and the deformation is small.
具体计算过程如下:The specific calculation process is as follows:
计算条件:Calculation conditions:
以图9中的截面为计算模型,表层薄板厚度取0.6mm,内部填充采用聚氨酯等发泡材料。Taking the section in Figure 9 as the calculation model, the thickness of the surface sheet is 0.6mm, and the interior is filled with foam materials such as polyurethane.
计算假定:Calculation assumptions:
A.内部填充发泡材料可以与表层薄板协同工作。A. The inner filling foam material can work together with the surface sheet.
B.外部环境温度(-20°~30°)对内部填充材料抗弯、抗压等强度无影响。B. The external environment temperature (-20°~30°) has no effect on the bending and compressive strength of the internal filling material.
C.表层薄板采用Q345钢材制作。C. The surface sheet is made of Q345 steel.
D.内部填充聚氨酯材料δ填充取30MpaD. The inner filling polyurethane material δ filling takes 30Mpa
E.计算图形和截面如图8所示。E. The calculated graphics and cross-sections are shown in Figure 8.
承载力计算:Calculation of bearing capacity:
抗弯承载力计算公式按下式模拟计算:The calculation formula of flexural bearing capacity is simulated by the following formula:
M=δ×W1+γ×δ×W2;其中,M=δ×W1+γ×δ×W2; where,
δ为卷制钢材屈服强度,可取值305Mpa;δ is the yield strength of rolled steel, which can be 305Mpa;
W1为卷制钢材截面模量,根据实际截面高度和宽度计算确定;W1 is the section modulus of rolled steel, which is calculated and determined according to the actual section height and width;
γ为材料强度折减系数,根据填充材料的不同而不同,取值0.5~0.9;γ is the strength reduction coefficient of the material, which varies according to the filling material, and the value is 0.5~0.9;
δ为填充材料屈服强度,如聚氨酯材料可取值30Mpa.;δ is the yield strength of the filling material, such as polyurethane material can take a value of 30Mpa.;
W2为填充材料截面模量,根据实际截面高度和宽度计算确定。W2 is the section modulus of the filling material, which is calculated and determined according to the actual section height and width.
有限元模拟如图10所示。The finite element simulation is shown in Figure 10.
有限元应力分析如图8所示。The finite element stress analysis is shown in Figure 8.
通过上面的计算机分析可以得出:Through the above computer analysis, we can get:
a、发泡填充材料与卷制钢材紧密结合共同受力,其中卷制钢材内填充材料根据整体截面形式、空腔体积、填充材料等的不同可提供约10~15%的承载力,有限元模拟值与理论计算值相符。a. The foamed filling material and the rolled steel are tightly combined to bear the force. The filling material in the rolled steel can provide about 10-15% of the bearing capacity according to the overall cross-sectional form, cavity volume, filling material, etc., finite element The simulation value agrees with the theoretical calculation value.
b、发泡材料为整体边框提供强度和稳定,使边框结构高度降低,优选的市场中常用72片组件的边框,采用本例边框高度可做到28mm以内,与常规高度为35-45mm铝边框有较大优势。b. The foamed material provides strength and stability for the overall frame, and reduces the height of the frame structure. The frame height of the 72 pieces of modules commonly used in the market is preferred. The frame height in this example can be within 28mm, compared with the conventional height of 35-45mm aluminum frame There is a big advantage.
本发明还提供了一种光伏组件,所述光伏组件包含上述的太阳能光伏组件用边框,由于改进点仅在边框上,因此,本发明不对光伏组件的其他结构进行详细地描述,均可以采用现有技术的结构。The present invention also provides a photovoltaic module. The photovoltaic module includes the above-mentioned frame for solar photovoltaic modules. Since the improvement is only on the frame, the present invention does not describe other structures of the photovoltaic module in detail, and all existing structures can be used. Technical structure.
本领域技术人员在考虑说明书及实践后,将容易想到本发明的其它实施方案。本申请旨在涵盖本发明的任何变型、用途或者适应性变化,这些变型、用途或者适应性变化遵循本发明的一般性原理并包括本发明未发明的本技术领域中的公知常识或惯用技术手段。说明书和实施例仅被视为示例性的,本发明的真正范围和精神由权利要求指出。Those skilled in the art will easily think of other embodiments of the present invention after considering the description and practice. This application is intended to cover any variations, uses, or adaptive changes of the present invention. These variations, uses, or adaptive changes follow the general principles of the present invention and include common knowledge or customary technical means in the technical field where the present invention is not invented. . The description and the embodiments are only regarded as exemplary, and the true scope and spirit of the present invention are pointed out by the claims.
Claims (12)
- 一种太阳能光伏组件用边框,包括闭合腔体,所述闭合腔体的上方设置有安装光伏组件的安装槽口;其特征在于,A frame for a solar photovoltaic module, comprising a closed cavity, and an installation notch for installing photovoltaic modules is arranged above the closed cavity; characterized in that,所述闭合腔体内设置有填充结构;A filling structure is provided in the closed cavity;所述边框选用钢板或金属合金板作为基材冷弯成型,其外表面设置有耐腐蚀的金属涂层,或采用涂刷涂料保护;或,The frame is cold-formed by using steel plate or metal alloy plate as the base material, and the outer surface of the frame is provided with a corrosion-resistant metal coating, or is protected by brushing paint; or,所述边框选用铝合金或镁合金作为基材挤压成型,所述铝合金、镁合金的表面进行氧化处理或采用涂刷涂料保护。The frame is extruded and formed by using aluminum alloy or magnesium alloy as a base material, and the surface of the aluminum alloy or magnesium alloy is oxidized or protected by brushing paint.
- 根据权利要求1所述的一种太阳能光伏组件用边框,其特征在于:所述闭合腔体的左框向上延伸形成竖边框,所述竖边框的顶部向右延伸形成顶边框;The frame for a solar photovoltaic module according to claim 1, wherein the left frame of the closed cavity extends upward to form a vertical frame, and the top of the vertical frame extends to the right to form a top frame;所述闭合腔体的下框向右延伸形成底边框;The lower frame of the closed cavity extends to the right to form a bottom frame;所述竖边框、顶边框、以及腔体的上框形成所述用于安装光伏组件的安装槽口。The vertical frame, the top frame, and the upper frame of the cavity form the installation slot for installing the photovoltaic module.
- 根据权利要求1所述的一种太阳能光伏组件用边框,其特征在于:所述闭合腔体的顶框向右延伸形成下边框,所述下边框向上延伸形成竖边框,所述竖边框向左延伸形成顶边框;The frame for a solar photovoltaic module according to claim 1, wherein the top frame of the closed cavity extends to the right to form a lower frame, the lower frame extends upward to form a vertical frame, and the vertical frame faces to the left. Extend to form a top frame;所述闭合腔体的下框向右延伸形成底边框;The lower frame of the closed cavity extends to the right to form a bottom frame;所述底边框、竖边框、顶边框、以及腔体的上框形成所述用于安装光伏组件的安装槽口。The bottom frame, the vertical frame, the top frame, and the upper frame of the cavity form the installation slot for installing the photovoltaic module.
- 根据权利要求1-3任一项所述的一种太阳能光伏组件用边框,其特征在于:所述填充结构采用有机发泡材料或无机发泡材料制作。The frame for a solar photovoltaic module according to any one of claims 1 to 3, wherein the filling structure is made of an organic foam material or an inorganic foam material.
- 根据权利要求4所述的一种太阳能光伏组件用边框,其特征在于:所述有机发泡材料为硬质聚氨酯泡沫塑料或不饱和聚酯塑料,所述不饱和聚酯塑料包括A和B两种组分,A组分包括不饱和聚酯树脂、增稠剂、引发剂、以及填料,B组分为玻璃纤维粗砂或玻璃纤维毡。The frame for a solar photovoltaic module according to claim 4, wherein the organic foaming material is rigid polyurethane foam plastic or unsaturated polyester plastic, and the unsaturated polyester plastic includes A and B. Components, A component includes unsaturated polyester resin, thickener, initiator, and filler, B component is glass fiber grit or glass fiber mat.
- 根据权利要求1或2所述的一种太阳能光伏组件用边框,其特征在于:所述竖边框、顶边框、以及底边框均卷制形成至少两层结构。The frame for a solar photovoltaic module according to claim 1 or 2, wherein the vertical frame, the top frame, and the bottom frame are all rolled to form at least a two-layer structure.
- 根据权利要求4所述的一种太阳能光伏组件用边框,其特征在于:所述边框的边缝处进行翻卷咬合、或焊接处理,以形成闭合腔体。The frame for a solar photovoltaic module according to claim 4, wherein the edge seam of the frame is rolled, snapped, or welded to form a closed cavity.
- 根据权利要求4所述的一种太阳能光伏组件用边框,其特征在于:在采用钢板或金属合金板卷制所述边框,或采用铝合金或镁合金挤压成型所述边框的过程中,在所述边框的腔体中设置填充结构进行发泡。The frame for a solar photovoltaic module according to claim 4, characterized in that: in the process of rolling the frame with steel plate or metal alloy sheet, or extruding the frame with aluminum alloy or magnesium alloy, The cavity of the frame is provided with a filling structure for foaming.
- 根据权利要求4所述的一种太阳能光伏组件用边框,其特征在于:所述边框的长边与短边的内连接处设置有第一连接件,所述第一连接件可拆卸地固定于所述底壁上,所述第一连接件用于同一个边框上的长边和短边之间的连接。The frame for a solar photovoltaic module according to claim 4, characterized in that: the inner connection of the long side and the short side of the frame is provided with a first connector, and the first connector is detachably fixed to On the bottom wall, the first connecting member is used for the connection between the long side and the short side on the same frame.
- 根据权利要求9所述的一种太阳能光伏组件用边框,其特征在于:所述边框的长边与短边的外连接处设置有第二连接件,所述第二连接件用于相邻边框之间的连接。The frame for a solar photovoltaic module according to claim 9, wherein a second connector is provided at the outer connection of the long side and the short side of the frame, and the second connector is used for the adjacent frame the connection between.
- 根据权利要求4所述的一种太阳能光伏组件用边框,其特征在于:所述边框的长边和短边在外侧边缝处采用焊接连接,所述焊接方式包括电阻焊、激光焊、或冷焊焊接。The frame for a solar photovoltaic module according to claim 4, wherein the long sides and short sides of the frame are connected by welding at the outer side seams, and the welding method includes resistance welding, laser welding, or cold welding. Welding.
- 一种光伏组件,其特征在于:所述光伏组件包含权利要求1-11任一项所述的太阳能光伏组件用边框。A photovoltaic module, characterized in that: the photovoltaic module comprises the frame for solar photovoltaic modules according to any one of claims 1-11.
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