SOLAR PANEL ASSEMBLY

专利摘要:
frame and support of plastic photovoltaic module and composition to prepare them. solar or photovoltaic module frames, supports, or frame or support components are prepared from a composition comprising (a) a thermoplastic polymer, particularly a thermoplastic polyolefin, (b) a reinforcing element, particularly fiberglass, (c) containing a non-halogen intumescent flame retardant, (d) an impact modifier, particularly a polyolefin elastomer, (e) a coupling agent, and optionally (f) one or more additives such as an antioxidant, UV stabilizer, etc. . these frames provide easy mounting without the need for screws, dowels or other metal fasteners.
公开号:BR112015031282B1
申请号:R112015031282-9
申请日:2013-06-28
公开日:2021-08-24
发明作者:Shaofu Wu；Yanli Huo；Yongjin Guo；Wenbin Yao；Zhiqing Lin；Jie Cai；Bin Chen；Yudong Qi；Libo Du；Hongyu Chen
申请人:Dow Global Technologies Llc；
IPC主号:

专利说明:

FIELD OF THE INVENTION
[001] This invention refers to photovoltaic (PV) modules and supports to assemble them. In one aspect, the invention relates to PV modules made of plastic while in another aspect, the invention relates to PV modules that are easily assembled into an array of PV modules without the need for nuts, screws or other metal fasteners. In one aspect, the invention relates to a plastic composition for preparing PV module frames and supports. BACKGROUND OF THE INVENTION
[002] Photovoltaic modules, also known as solar modules, are constructions for the direct generation of electricity from sunlight. They comprise, among other components, one or more, usually a plurality, of PV or solar cells in a frame. The frame provides mechanical support for the PV cells against mechanical forces such as wind. The frame and supports on which a plurality of PV modules are mounted in a PV modular matrix require good mechanical strength and thermal dimensional stability.
[003] Currently, aluminum is the material of choice for PV module frames and supports due to its relatively low cost and high mechanical strength. However, aluminum has several disadvantages. Due to their conductive nature, PV modules with an aluminum frame can experience leakage currents, and leakage current can degrade the conductive layer of the PV cell. Furthermore, aluminum PV frames (and brackets) need to be grounded for safety reasons, and this can become a serious cost issue for applications with many modules, eg for solar parks. Also, aluminum is heavy compared to other materials, eg plastics, and usually the lighter the frame, the better.
[004] Recently, a number of companies manufacturing PV module frames have begun to explore the replacement of aluminum with any, or combination, of various polymers such as polyamide (PA), polyphenylene ether/polystyrene (PPE/PS), polyamide /polybutylene terephthalate (PBT/PA), and polyamide/polyphenylene ether/polystyrene (PA/PPE/PS), fiberglass reinforced acrylonitrile/styrene/acrylate (ASA) (available from BASF), and polyurethane systems (available Bayer). However, not only the search continues for useful plastics in this application, but also for better frame and support designs.
[005] Aluminum bracket frames often comprise many parts that require assembly with screws, nuts and other metal fasteners and these, in turn, can prepare for slow and inefficient assembly. Junction boxes are not integrated into the frame and therefore require separate accessories. Many long power cables are often needed to connect modules together in an array. Concrete pillars or ballasts are often needed to secure modules or an array of modules for a base. These and other considerations lead to a desire for not only a non-metal material for PV module frames and supports, but also for better PV module frame and support designs. SUMMARY OF THE INVENTION
[006] In one embodiment, the invention is a composition comprising (A) a thermoplastic polymer, particularly a thermoplastic polyolefin (TPO), (B) a reinforcing element, particularly fiberglass, (C) a flame retardant containing no halogen, intumescent, (D) an impact modifier, (E) a coupling agent and optionally (F) one or more additives such as an antioxidant, UV stabilizer, etc.
[007] In one embodiment, the invention is a frame, support, or frame or support component prepared from a composition comprising (A) a thermoplastic polymer, particularly a thermoplastic polyolefin (TPO), (B) a reinforcing element, particularly fiberglass, (C) a non-halogen-containing, intumescent flame retardant, (D) an impact modifier, particularly a polyolefin elastomer other than the thermoplastic polymer of (A), (E) a coupling agent and, optionally (F) one or more additives such as an antioxidant, UV stabilizer, etc.
[008] In one embodiment, the invention is a solar panel assembly comprising a: (A) PV module comprising one or more PV cells within a plastic frame, and the frame comprising plastic fittings front and rear base, the fittings of front base hingedly attached to the PV module frame and the rear base accessories slidably engaged with the PV module frame; (B) Plastic base comprising two separate mounting bases joined by a connector plate, each mounting base equipped with plastic front pins to pivotally engage the PV module frame front base fittings, and rear couplings engaged in a mating relationship with the PV module rear base fittings; (C) Plastic wind deflector engaged in a mating relationship with each of the two rear base accessories; (D) Plastic junction box integral with PV module frame; and(E) Two plastic self-aligning devices for joining adjacent PV modules to each other, each device integral with the PV module frame.
[009] In one embodiment, the invention is a plastic PV module frame characterized by (A) a unitary overmolded or molded part, (B) an L-shape, (C) a two-piece junction box with a piece located on one side of the frame and the other piece located opposite and on the other side of the frame; (D) a self-aligning device, and (E) at least one structural member at the rear of the panel to provide mechanical strength to the panel.
[0010] In one embodiment, the invention is a photovoltaic assembly comprising: (A) A solar panel module comprising a back support, a front support and an absorbent layer between the front support and the back support; (B) Piece frame single, integrated, molded around the module; (C) A junction box integrated in the frame; (D) An entrance at one end of the frame through which the module can be inserted into the frame; (E) A sealing block or cover over inlet and engaged with frame in a mating relationship; e(F) A sealing position between the frame cover and the inserted module. BRIEF DESCRIPTION OF THE DRAWINGS
[0011] Figures 1A and 1B illustrate two conventional solar panel arrays, mounted on a bracket.
[0012] Figures 1C and 1D illustrate conventional support configurations on which the solar panel arrays of Figures 1A-B are attached.
[0013] Figure 1E is a conventional metal fastener by which a solar panel is attached to a bracket.
[0014] Figures 2A and 2B illustrate the front and rear, respectively, of a conventional solar panel.
[0015] Figures 2C and 2D illustrate the metal screws and metal corner inserts, respectively, used to construct the metal frame of the solar panel of Figures 2A-B.
[0016] Figure 2E illustrates the solar panel grounding assembly of Figures 2A-B.
[0017] Figure 3A is an exploded view of one embodiment of a solar panel assembly and its support base of this invention.
[0018] Figure 3B is an illustration of an integrated or sewn junction box of the solar panel assembly of Figure 3A.
[0019] Figure 3C is an illustration of an integrated electrical door of the solar panel of Figure 3A.
[0020] Figures 3D-E further illustrate mounting bases 38A-B of Figure 3A.
[0021] Figure 3F illustrates the attachment of the solar panel to the mounting base.
[0022] Figure 3G illustrates the engagement of the rear elevation of the frame base with the rear base accessory.
[0023] Figure 3H illustrates the attachment of the rear base accessories to the solar panel mounting frame.
[0024] Figure 3I illustrates the engagement of the wind deflector with the rear base accessories.
[0025] Figure 3J illustrates two solar panel assemblies with their brackets positioned together in an array.
[0026] Figure 4A illustrates a PV module comprising an L-shaped frame, junction boxes, self-aligning devices and structural beams.
[0027] Figures 4B and 4C illustrate the coupling of an alignment device in a PV module with an alignment device in an adjacent module.
[0028] Figure 4D illustrates the positioning of structural beams at the rear of a photovoltaic array.
[0029] Figures 5A, 5B, 5C and 5D illustrate a PV module frame comprising (i) a backsheet with an integrated junction box and (ii) cross-locking.
[0030] Figures 5E-F illustrate inside and outside views, respectively, of a corner connector.
[0031] Figure 5G provides a cross-sectional view of a corner connector engaged with an edge frame and laminated solar panel.
[0032] Figures 5H-J illustrate the portion of a solar panel array for a roof or similar structure.
[0033] Figures 6A-B illustrate a PV module with a (i) front part comprising four frame sections and a solar cell array and, (ii) rear side comprising four frame sections and four corner connectors, respectively.
[0034] Figures 6C and 6D illustrate a corner connector.
[0035] Figure 6E illustrates a frame with a cutout that corresponds in size and shape to a tab on the corner connector.
[0036] Figures 6F, 6G and 6H illustrate the way in which a corner connector couples or joins two sections of a PV module frame.
[0037] Figure 6I illustrates the welding of two frame sections together, once joined by a corner connector.
[0038] Figures 7A and 7B illustrate an integrated PV module having a hinge and snap construction.
[0039] Figures 7C-D are open and closed fitting frame/lid schemes, respectively.
[0040] Figures 7E-F are alternate open and closed frame/lid fitting schemes, respectively for the embodiment of Figures 7C-D.
[0041] Figures 8A, 8B and 8C illustrate a cast molded PV module with an integrated backsheet and junction box.
[0042] Figures 9A-F show steps in an embodiment of a process in which a solar panel is overmolded with a plastic frame.
[0043] Figure 10A shows a PV module with extended support legs attached to a frame by hinges.
[0044] Figure 10B shows the PV module of Figure 10A with the support legs folded back against the rear side of the module.
[0045] Figures 10C-D show support legs bent into channels of the module frame.
[0046] Figure 10E shows the extended legs of a PV module locked in place with side arms.
[0047] Figure 10F shows the rear support legs of a PV module with telescopic functionality to allow height adjustment of the module.
[0048] Figure 11A shows an exploded view of an embodiment of a PV module of this invention.
[0049] Figure 11B shows the PV module of Figures 11A in assembled form.
[0050] Figure 11C shows a pressure closing mode of the PV module of Figures 11A-B.
[0051] Figure 12 illustrates a PV module with chimney gaps. DETAILED DESCRIPTION OF THE PREFERRED MODE Definitions
[0052] Unless otherwise indicated, implied by the context, or customary in the art, all parts and percentages are by weight. For purposes of United States patent practice, the contents of any referenced patent, patent application, or publication are incorporated by reference in their entirety (or its equivalent US version is incorporated by reference) especially with respect to the disclosure of synthetic techniques , definitions (to the extent that they are not inconsistent with any definitions specifically provided for in this disclosure), and general knowledge in the art.
[0053] The numerical ranges in this disclosure are approximate and, therefore, may include values outside the range, unless otherwise indicated. Numeric ranges include all values of and including lower and upper values, in increments of one unit, provided there is a separation of at least two units between any lower and any higher values. As an example, if a composition, physical or other property, such as molecular weight, viscosity, melt index, is 100 to 1,000, all individual values such as 100, 101, 102, etc. are intended. and subranges, such as 100 to 144, 155 to 170, 197 to 200, etc., are expressly listed. For ranges containing values that are less than one or containing fractional numbers greater than one (eg 1.1, 1.5, etc.), a unit is considered to be 0.0001, 0.001, 0.01 or 0, 1, as appropriate. For ranges containing single digit numbers less than ten (eg 1 to 5), a unit is normally considered to be 0.1. These are just examples of what is specifically intended, and all possible combinations of numerical values between the lowest and highest enumerated values are considered to be expressly stated in this disclosure. Numerical ranges are provided within this disclosure for, among other things, the relative quantities of the various components in the composition from which the PV module frames and holders are manufactured.
[0054] “Using”, “including”, “having” and derivatives are not intended to exclude the presence of any additional component, step or procedure, regardless of whether it is specifically disclosed. For the avoidance of doubt, all compositions claimed by the use of the term "comprising" may include any additive, adjuvant or additional compound, polymeric or not, unless otherwise indicated. In contrast, the term, "consisting essentially of" excludes from the scope any recitation following any other component, step, or procedure, except those that are not essential to operability. The term “consists of” excludes any component, step or procedure not specifically delineated or listed. plastic composition
[0055] In one embodiment, the invention is a composition comprising (A) a thermoplastic polymer, (B) a reinforcing element, (C) a non-halogen-containing flame retardant, intumescent, (D) an impact modifier, ( E) a coupling agent and optionally (F) one or more additives. In one embodiment, the invention is a composition comprising, based on the weight of the composition (A) 10-80% by weight of a thermoplastic polymer, (B) 10-55% by weight of a reinforcing element, (C) 1- 30% by weight of a non-halogen intumescent flame retardant, (D) 1-20% by weight of an impact modifier, (E) 0.001-0.5% by weight of a coupling agent, and optionally (F) one or more additives.
[0056] In one embodiment, the invention is a photovoltaic (PV) frame, PV support, or PV frame component or PV support prepared from a composition comprising (A) a thermoplastic polymer, particularly a thermoplastic polyolefin (TPO), (B ) a reinforcing element, particularly fiberglass, (C) a non-halogen-containing, intumescent flame retardant, (D) an impact modifier, particularly a polyolefin elastomer other than the thermoplastic polymer of (A), (E) ) an uncoupling agent and optionally (F) one or more additives such as an antioxidant, UV stabilizer, etc. In one embodiment, the invention is a photovoltaic (PV) frame, PV support, or PV frame component or PV support prepared from a composition comprising, based on the weight of the composition (A) 10-80% by weight of a thermoplastic polymer , (B) 10-55% by weight of a reinforcing element, (C) 1-30% by weight of a non-halogen intumescent flame retardant, (D) 1-20% by weight of an impact modifier, (E) 0.001-0.5% by weight of a coupling agent and optionally (F) one or more additives.
[0057] Non-limiting examples of suitable thermoplastic polymers include, among others, olefin-based polymers, polyamides, polycarbonates, polyesters, thermoplastic polyurethanes, thermoplastic polyesters, polystyrenes, high impact polyesters, polyphenylene oxide, and any combination thereof. In one embodiment, the thermoplastic polymer is a halogen-free polymer. As used herein, "halogen free" means the absence of a halogen other than that which may be present as a contaminant.
[0058] In one embodiment, the thermoplastic polymer is an olefin-based polymer. As used herein, an "olefin-based polymer" is a polymer containing, in polymerized form, an olefin, for example, ethylene or propylene. The olefin-based polymer may contain a percentage of the main weight of the polymerized form of the olefin based on the total weight of the polymer. Non-limiting examples of olefin-based polymers include ethylene-based polymers and propylene-based polymers. In one embodiment, the olefin-based polymer is an ethylene-based polymer. Non-limiting examples of suitable ethylene-based polymers include ethylene/α-olefin copolymer (ethylene/propylene copolymer, ethylene/butene copolymer, ethylene/octene copolymer), ethylene/(acrylic acid) copolymer, ethylene/copolymer methylacrylate, ethylene/ethylacrylate copolymer, ethylene/vinyl acetate copolymer, ethylene/propylene/diene copolymer, and any combination thereof. In one embodiment, the olefin-based polymer is a propylene-based polymer. Non-limiting examples of suitable propylene-based polymers include propylene homopolymers and propylene copolymers including impact modified polypropylene (IPP). The thermoplastic polymer provides flexibility, solvent resistance, thermal stability and/or mechanical strength to the final composition.
[0059] In one embodiment, the thermoplastic polymer is an ethylene/α-olefin copolymer, an ethylene olefin/α-olefin block copolymer, or a combination thereof. In one embodiment, the thermoplastic polymer is an ethylene/butene copolymer. In one embodiment, the thermoplastic polymer is an ethylene olefin/α-olefin block copolymer.
[0060] In one embodiment, the thermoplastic polymer is an IPP. Impact modified polypropylene is a known polymer and comprises at least two main components, Component A and Component B. Component A is preferably an isotactic propylene homopolymer, although small amounts of a comonomer may be used to obtain particular properties. Typically such Component A copolymers contain 10% by weight or less, preferably less than 6% by weight or less, of comonomer such as ethylene, butene, hexene or octene. More preferably less than 4% by weight of ethylene is used. The end result is typically a product with less stiffness but some gain in impact strength compared to Component A homopolymer.
[0061] As used herein, Component A generally refers to the insoluble xylene portion of the IPP composition, and component B generally refers to the soluble xylene portion. Where the soluble portion of xylene clearly has a high molecular weight component and a low molecular weight component, the low molecular weight component is attributable to low molecular weight, amorphous propylene homopolymer. Therefore, Component B in these circumstances refers only to the high molecular weight portion.
[0062] Component B is most preferably a copolymer consisting essentially of propylene and ethylene, although other propylene copolymers, ethylene copolymers or terpolymers may be suitable depending on the particular product properties desired. For example, propylene/butene, hexene or octene copolymers, ethylene/butene, hexene or octene copolymers can be used, and propylene/ethylene/hexene-1 terpolymers can be used. In a preferred embodiment, Component B is a copolymer comprising at least 40% by weight of propylene, more preferably from 80% by weight to 30% by weight of propylene, even more preferably from 70% by weight to 35% by weight of propylene . The comonomer content of Component B is preferably in the range from 20% to 70% by weight of comonomer, more preferably from 30% to 65% by weight of comonomer, most preferably from 35% to 60% by weight of comonomer. More preferably, Component B consists essentially of propylene and from 20% to 70% ethylene, more preferably from 30% to 65% ethylene, and most preferably from 35% to 60% ethylene.
[0063] In one embodiment, the thermoplastic polymer typically comprises from 10 to 80, more typically from 25 to 70, percent by weight (% by weight) of the composition.
[0064] Non-limiting examples of suitable reinforcing elements include, among others, glass fibers, carbon fibers, talc, calcium carbonate, organophilic clay, marble powder, cement powder, feldspar, silica or glass, fumed silica, silicates, alumina, ammonium bromide, antimony trioxide, antimony trioxide, zinc oxide, zinc borate, barium sulfate, silicones, aluminum silicate, calcium silicate, titanium oxides, glass microspheres, chalk, mica, clays, wollastonite, ammonium octamolybdate, intumescent compounds, expandable graphite, and mixtures thereof. Reinforcing elements can contain various coatings or surface treatments such as silane, fatty acids, and the like. Fiberglass, particularly long fiberglass, is the preferred reinforcing element.
[0065] In one embodiment, the reinforcing element typically comprises from 10 to 55, more typically from 25 to 40, percent by weight (% by weight) of the composition.
[0066] In one embodiment, the non-halogen intumescent (FR) flame retardant system used in the practice of the present invention comprises one or more intumescent FR based on organic phosphorus and/or based on nitrogen, optionally including a component of piperazine. In one embodiment, the intumescent, halogen-free FR system typically comprises from 1 to 30, more typically from 5 to 25, percent by weight (% by weight) of the composition.
[0067] In one embodiment, the non-halogen, intumescent FR system comprises at least 1, 10, 15, 20 and more preferably at least 30% by weight of a phosphorus/organic nitrogen-based compound. The typical maximum amount of the phosphorus/organic nitrogen-based compound does not exceed 70, 60, 50, and more preferably does not exceed 45. % by weight of the non-halogen, intumescent FR system.
[0068] In one embodiment of the non-halogen FR system, intumescent comprises 30-99% by weight of a piperazine-based compound. The preferred amount of the piperazine-based compound is at least 30, 40, and at least 50% by weight. In particular embodiments, the FR system may comprise 55-65% by weight of a piperazine-based compound and 35-45% by weight of one or more other flame retardants (e.g., a phosphorus/organic nitrogen-based compound).
[0069] Non-limiting examples of suitable non-halogen flame retardants, suitable intumescents include, but are not limited to, organic phosphonic acids, phosphonates, phosphinates, phosphonites, phosphinites, phosphine oxides, phosphines, phosphites or phosphates, phosphonitrile chloride, phosphoric ester amides , phosphoric acid amides, phosphonic acid amides, phosphinic acid amides, and melamine and melamine derivatives, including melamine polyphosphate, melamine pyrophosphate and melamine cyanurate, and mixtures of two or more of these materials. Examples include phenylbisdodecyl phosphate, phenylbisneopentyl phosphate, phenyl ethylene hydrogen phosphate, phenyl-bis-3,5,5'-trimethylhexyl phosphate), ethyldiphenyl phosphate, 2-ethylhexyl di(p-tolyl) phosphate, diphenyl hydrogen phosphate, bis(2- ethylhexyl) p-tolyl phosphate, tritolyl phosphate, bis(2-ethylhexyl)-phenyl phosphate, tri(nonylphenyl) phosphate, phenylmethyl hydrogen phosphate, di(dodecyl) p-tolyl phosphate, tricresyl phosphate, triphenyl phosphate, triphenyl phosphate, dibutylphenyl phosphate, 2-chloroethyldiphenyl phosphate, p-tolyl bis(2,5,5'-trimethylhexyl) phosphate, 2-ethylhexyldiphenyl phosphate, and diphenyl hydrogen phosphate. Phosphoric acid esters of the type described in USP 6,404,971 are examples of phosphorus-based FRs. Additional examples include liquid phosphates such as bisphenol A diphosphate (BAPP) (Adeka Palmarole) and/or resorcinol bis(diphenyl phosphate) (Fyroflex RDP) (Supresta, ICI) and solid phosphorus such as ammonium polyphosphate (APP), piperazine pyrophosphate, orthophosphate of piperazine and piperazine polyphosphate. APP is often used with flame retardant coadditives such as melamine derivatives. Melafine (DSM) (2,4,6-triamino-1,3,5-triazine; fine-grind melamine) is also helpful.
[0070] Examples of the optional piperazine components of the FR system include compounds such as piperazine pyrophosphate, piperazine orthophosphate, and piperazine polyphosphate. Additional examples include polytriazinyl compounds or 1,3,5-triazine oligomer derivatives or polymers including a piperazine group, as described in US 2009/0281215 and WO 2009/016129.
[0071] Impact modifiers are materials added to a substance to improve the substance's resistance to deformation and/or breakage. In the context of improving plastic's resistance to deformation and/or breakage, non-limiting examples of impact modifiers include natural and synthetic rubbers (eg ethylene propylene rubbers (EPR or EPDM)), ethylene vinyl acetate (EVA) , styrene-block copolymers (SBC), polyvinyl chloride (PVC) and polyolefin elastomers (POE).
[0072] While any elastomeric polyolefin can be used in the practice of this invention, preferred elastomeric polyolefins are prepared with a single-site catalyst such that a metallocene catalyst of constrained catalyst geometry typically has a melting point of less than 95, preferably less than 90, more preferably less than 85, even more preferably less than 80 and even more preferably less than 75°C.
[0073] Elastomeric polyolefin copolymers useful in the practice of this invention include ethylene/α-olefin interpolymers having an α-olefin content of between 15, preferably at least 20 and even more preferably at least 25% by weight based on interpolymer weight. Such interpolymers typically have an α-olefin content of less than 50, preferably less than 45, more preferably less than 40 and even more preferably less than 35.% by weight based on the weight of the interpolymer. α-Olefin content is measured by 13 C nuclear magnetic resonance (NMR) spectroscopy using the procedure described in Randall (Rev. Macromol. Chem. Phys., C29 (2&3)). Generally, the higher the α-olefin content of the interpolymer, the lower the density and the more amorphous the interpolymer is, and this translates into desirable physical and chemical properties as an impact modifier.
[0074] The α-olefin is preferably a linear, branched or cyclic C3-20 α-olefin. The term interpolymer refers to a polymer made from at least two monomers. It includes, for example, copolymers, terpolymers and tetrapolymers. Examples of C3-20 α-olefins include propene, 1-butene, 4-methyl-1-pentene, 1-hexene, 1-octene, 1-decene, 1-dodecene, 1-tetradecene, 1-hexadecene, and 1- octadecene. α-Olefins can also have a cyclic structure such as cyclohexane or cyclopentane, resulting in an α-olefin such as 3-cyclohexyl-1-propene (allyl cyclohexane) and vinyl cyclohexane. Although not α-olefins in the classical sense of the term, for the purposes of this invention, certain cyclic olefins, such as norbornene and related olefins, particularly 5-ethylidene-2-norbornene, are α-olefins and can be used in place of some or all of the olefins. α-olefins described above. Likewise, styrene and its related olefins (eg, α-methylstyrene, etc.) are α-olefins for the purposes of this invention. Illustrative polyolefin copolymers include ethylene/propylene, ethylene/butene, ethylene/1-hexene, ethylene/1-octene, ethylene/styrene, and the like. Illustrative terpolymers include ethylene/propylene/1-octene, ethylene/propylene/butene, ethylene/butene/1-octene, ethylene/propylene/diene monomer (EPDM) and ethylene/butene/styrene. Copolymers can be random or block.
[0075] Elastomeric polyolefin copolymers useful in the practice of this invention have a glass transition temperature (Tg) of less than -20, preferably less than -40, more preferably less than -50 and even more preferably less than -60, C as measured by differential scanning calorimetry (DSC) using the procedure of ASTM D-3418-03. In addition, typically the elastomeric polyolefin copolymers used in the practice of the present invention also have a melt index (as measured by ASTM D-1238 (190°C/2.16 kg)) of less than 100, preferably less than 75. more preferably less than 50 and even more preferably less than 35 g/10 minutes. The typical minimum MI is 1, and most is typically 5.
[0076] More specific examples of elastomeric olefinic interpolymers useful in this invention include very low density polyethylene (VLDPE) (eg FLEXOMER ethylene/1-hexene polyethylene prepared by The Dow Chemical Company), homogeneously branched ethylene/α-olefin copolymers , linear (e.g., TAFMER by Mitsui Petrochemicals Company Limited and EXACT by Exxon Chemical Company), and substantially linear, homogeneously branched ethylene/α-olefin polymers (e.g., AFFINITY and ENGAGE polyethylene available from The Dow Chemical Company). The most preferred elastomeric polyolefin copolymers are linear and substantially linear homogeneously branched ethylene copolymers. Substantially linear ethylene copolymers are especially preferred, and are more fully described in USP 5,272,236, 5,278,272 and 5,986,028.
[0077] While the thermoplastic polymer (the A component of the composition) and the impact modifier (the D component of the composition) may be a polyolefin elastomer, they are never the same polyolefin elastomer in any given composition. In other words, if the thermoplastic polymer is an ethylene-propylene copolymer, then the impact modifier is something different from an ethylene-propylene copolymer, for example, an ethylene-butene copolymer, or an ethylene-octene copolymer, or an EPDM, etc. In one embodiment, the composition comprises an IPP as the thermoplastic polymer (component A) and a substantially linear ethylene copolymer, e.g., an ENGAGE elastomer, as the impact modifier (component D).
[0078] In one embodiment, the impact modifier typically comprises from 1 to 20, more typically from 5 to 15, % by weight of the composition.
[0079] In one embodiment, coupling agents used in the composition of this invention include, among others, bis(sulfonyl azide) (BSA), ethylene vinyl acetate (EVA) copolymer (e.g., ELVAX 40L-03 (40%VA) , 3MI) by DuPont) and amine olefin block copolymers (eg INFUSE 9807 by The Dow Chemical Company). Examples of other coupling agents include polysiloxane containing vinyl and ethoxy groups (eg DYNASYLAN 6498 (oligomeric vinyl silane)) and hydroxy-terminated dimethylsiloxane (<0.1 vinyl acetate). In one embodiment, the coupling agent typically comprises from 0.001 to 0.5% by weight of the composition.
[0080] The compositions of this invention may incorporate one or more stabilizers and/or additives such as, among others, antioxidants (e.g. hindered phenols such as IRGANOX™ 1010 (Ciba/BASF), thermal stabilizers (melting processing), stability enhancers hydrolytic, heat stabilizers, acid cleaners, dyes or pigments, UV stabilizers, UV absorbers, nucleating agents, processing aids (such as oils, organic acids such as stearic acid, metallic salts of organic acids), antistatic agents, smoke suppressors , hardening anti-drip agents, plasticizers (such as dioctylphthalate or epoxidized soybean oil), lubricants, emulsifiers, optical brighteners, silanes (in free form or as a filler surface modifier), cement, urea, polyalcohols such as pentaerythritol, minerals, peroxides, stabilizers light (such as hindered amines), mold release agents, waxes (such as polyethylene waxes), mould. viscosity modifiers, carbonizing agents (e.g. pentaerythritol) and other additives, insofar as these additives do not interfere with the desired physical or mechanical properties of articles made from the compositions of the present invention. If present, then these additives are used in known amounts and in known ways, but normally the additive, or additive package, comprises greater than zero, eg 0.01, to 2, more usually 0.1 to 1, % by weight of the final composition. Examples of useful viscosity modifiers include polyether polyols such as VORANOL 3010 and VORANOL 222-029, available from The Dow Chemical Company). Useful commercially available anti-drip agents include triglycidyl isocyanurate (TGIC), VIKOFLEX 7010 (methyl epoxy soyate (epoxidized ester family)), and VIKOLOX epoxy alpha olefin (C-16) (mixture of 1,2 epoxyhexadecane (>95) % by weight) and 1-hexadecene (<5% by weight), both available from eFAME A useful metal dispersant/chelant is n-octylphosphonic acid (UNIPLEX OPA).
[0081] Combining the compositions of this invention can be accomplished by standard means known to those skilled in the art. Examples of compounding equipment are internal batch mixers, eg BANBURY or BOLLING internal mixer. Alternatively, continuous single or twin screw mixers can be used, for example FARREL continuous mixer, WERNER and PFLEIDERER twin screw mixer, or BUSS continuous kneading extruder. The type of mixer used, and the mixer operating conditions will affect composition properties such as viscosity, volume resistivity, and softness of the extruded surface. The temperature of the polymer blend composition with the FR and optional additive packages is usually 120° to 220°C, more typically 160° to 200°C. The various components of the final composition can be added to and combined with one another in any order, or simultaneously, but typically a compatibilizer (if included) is first combined with the IPP and the thermoplastic polymer is first combined with one or more of the components of the FR package, and the two mixtures with all the remaining components of the FR package and any additives are combined together. In some embodiments, additives are added as a premixed masterbatch, which is usually formed by dispersing the additives, separately or together, in an inert plastic resin, for example, one of IPP or thermoplastic polymer. Standard batches are conveniently formed by melt blending methods. PV Module and Support
[0082] The following drawings illustrate various embodiments of the prior art and the invention. Like components and parts have like numbers in all drawings.Prior Technique
[0083] Figures 1A and 1B illustrate two prior art conventional solar panel arrays. In each illustration, a multiple of solar panels 11 are attached to the bracket or matrix frame 12 (shown in Figures 1C and 1D) in a grid configuration. The matrix support 12 comprises metal, normally aluminum, cross support 12a and metal, normally aluminum, trusses 12b mounted to receive and hold a plurality of solar panels 11. The solar panels are attached to the support 12 in any conventional, usually conventional manner. by a plurality of metallic fasteners 13 as illustrated in Figure 1E. Other means of securing the solar panels to the array support include nuts, screws, and soldering (not shown). Each solar panel requires leveling at the time it is attached to the array bracket to ensure alignment with the other attached solar panels and since the array bracket is mostly, if not all, metal, it requires grounding (not shown ). If the matrix support is placed on top of a roof, then ballast (not shown) is normally needed to hold it in place. If the matrix support is placed on top of the ground then normally a concrete or metal pillar is also required.
[0084] Figures 2A and 2B illustrate the front 21A and rear 21B, respectively, of the solar panel 21. The solar panel 21 comprises metal, usually aluminum, frame portions 24A-D that are joined at the corners or with metal screws 25A -B as illustrated in Figure 2C, or by inserting into the metal corner 26 as illustrated in Figure 2D. Since the solar panel frame is metal, it, as a metal matrix bracket, also requires grounding as shown in Figure 2E with ground screw 27A, ground nut 27B-C, and attached ground wires 27D-E apart from frame 24A. At the rear of the solar panel 21B is attached junction box 28 (Figure 2B) which collects the energy produced by photovoltaic cells 29 (Figure 2A) for transfer to a final application or electrical grid.First Mode: PV Module and Support
[0085] Figure 3A is an exploded view of one embodiment of a solar panel assembly and its support base of this invention. Solar panel assembly 31 comprises photovoltaic array 32 (view from rear), integrated junction box or seam 33 (Figure 3B), electrical door 34 (Figure 3C), front base attachments 35A 35B, rear base attachments 35C and 35D, and wind deflector 36. The front and rear base attachments can fold flat against the rear of the PV array, and the front base attachments are typically shorter, typically more than 50% shorter than the PV array attachments. back base. Bracket 37 comprises bracket mounting bases 38A and 38B which are joined together by middle connector plate 39.
[0086] Figure 3D further illustrates the mounting base 38B as comprising frame base 41B with front elevation 42B and rear elevation 43B. Frame base 41B is equipped with holes 44B sized and molded to receive a mating ratio of the pins (not shown) of the middle connector plate 39 to allow for joining of mounting bases 38A and 38B as shown in Figures 3A and 3E . The 42B frame base front lift is equipped with pins 45B to engage hole 46B on the front base attachment 35B. The 42A frame base front lift is designed in a similar manner to the 42B frame base front lift to support the solar panel assembly 31 and allow it to hinge over pins 45A and 45B. The engagement of hole 35A and pin 45A is illustrated in Figure 3F.
[0087] As shown in Figure 3G, the rear elevation of the frame base 43B comprises the slit 47B that is sized and molded to receive in a mating relationship the rear base attachment 35D. The rear frame base lift 43A is designed in a similar manner to the rear frame base lift 43B to support the solar panel assembly 31 and allow it to hinge over pins 45A and 45B. In connection with this hinge feature, rear base fittings 35C and 35D engage the solar panel mounting frame 31 in a way that allows the panel to slide over these rear base fittings as the front base fittings rotate on the pins 45A and 45B. The attachment of the rear base accessories to the solar panel mounting frame is illustrated in Figure 3H. The rear base fitting 35D comprises the crown 48 sized and molded to receive the slider 49 which is affixed to the solar panel mounting frame 52. This combination of pivoting and sliding the solar panel mounting eliminates the need for leveling the panel with respect to other panels in the matrix, and allows an easy response to wind and other forces that could disrupt installation alignment.
[0088] Rear base accessories 35C and 35D also comprise slits for receiving and holding the wind deflector height edges 36. This is illustrated in Figure 3I with the engagement of a wind deflector height edge 36 with the slit 51 of the 35D Rear Base Attachment.
[0089] Figure 3J illustrates two solar panel assemblies with their brackets positioned together in an array. Mounts and brackets are held in position with ballast 53 which is placed on adjacent frame bases. (A) Second Mode: PV Module and Bracket
[0090] In an embodiment of the invention, the PV module frame is characterized by one or more of the following characteristics: (A) a single molded or overmolded part, (B) an L-shape, (C) a box of joining two pieces with one piece located on one side of the frame and the other piece located opposite and on the other side of the frame; (D) no observable wires on the rear side of the panel (from the perspective of looking at the front side of the panel), (E) a self-aligning device, and (E) at least one structural member on the rear of the panel to provide mechanical strength to the panel. In one embodiment, the PV module of this invention is characterized by two, or three, or four, or five, or all six of these features which are more fully described in Figures 4A-D.
[0091] In Figure 4A, the PV module 54 comprises an L-shaped frame 55, junction boxes 56A-D, self-aligning devices 57A-D (only 57B and 57D are shown) and structural beams 58A-B. Junction boxes and self-aligning devices are integrated into the semi-frame, for example, they are part of the molded semi-frame. One junction box moves electricity into the module, and the other junction box moves electricity outside the module. As shown in Figures 4B and 4C, the alignment device of one module is coupled to the alignment device of an adjacent module. One aligning device, eg 57A, is equipped with a female end, while the other aligning device, eg 57B, is equipped with a male end. Devices are positioned on each module so that the female alignment device of one module is opposite the male alignment device of the adjacent module. The male and female alignment devices are sized and molded to allow a snap-in joint that, when fitted together, locks modules adjacent to each other and in the desired alignment. When the alignment devices are locked together, they protect the short wire, for example 59 in Figure 4B, which connects from a junction box of one module to an adjacent module's junction box.
[0092] The PV module 54 is also equipped with structural beams 58A and 58B. In one modality, the PV module is equipped with a beam. In another modality, the PV module is equipped with more than two beams. In one modality, the PV module is without a beam. Structural beams, when present, provide mechanical strength to the photovoltaic array.
[0093] As shown in Figure 4D, the structural beams are positioned at the rear of the photovoltaic array and within the long edges of the module. These structural beams are sized and molded to engage rails 61A and 61B, respectively, so these beams 58A and 58B slide over or into rails 61A and 61B. Both structural beams 58A-B and rails 61A-B are normally tubular and comprise slits which, when aligned on top of each other, allow insertion of a pin or other locking device 62A-D into both structures, thus locking into each other in a fixed position. The rails are normally C-shaped, that is, one side of the rail is open to receive the structural beam, but the gap is sized so that the beam must be inserted or removed from one end of the rail, not from a region between. the ends of the rail. This feature reduces or eliminates the need for screws, nuts and the like to attach the PV module to a matrix bracket or other frame and with the built-in self-aligning devices and junction boxes reduces assembly time and effort.
[0094] The assembly of the frame is simple and quick. The L-shaped frame is placed on a flat surface with the open side up, that is, one leg of the L flat on the surface and the other leg of the L extending perpendicularly upward. A sealant is applied to the interior of the frame and/or the edges of the PV array panel, and then the panel is inserted into the open frame so that the sealant is between the edges of the panel and the frame. The sealer is then allowed to cure so that the panel is firmly affixed to the frame.
[0095] The structural beams are then inserted and affixed to the frame by any convenient method, eg mechanical fastener, compression fit, adhesive, etc., and the assembled module is then slid onto the rails. The modules are snapped together using the alignment devices, the junction boxes coupled with a soft wire, eg 49 in Figure 4B, or snapped together if the junction boxes are equipped with this connection (not shown), and the module PV is then fixed to the rails with snap pins.
[0096] The L-shaped frame allows the construction of a PV module with a smaller footprint (eg 2.5% or more) because less space is needed between the edge of the photovoltaic array and the frame. This reduces module weight and construction cost.Third Modality: PV Module and Anchor Blocks
[0097] In one embodiment of the invention, the PV module frame comprises a (i) backsheet, preferably with an integrated junction box, and (ii) four straight-sided frame segments joined in a rectangular configuration by four connectors. corner. The back sheet can be laminated with solar cell layers. PV modules can be fixed to a matrix through the use of cross anchor blocks.
[0098] The PV module, frame and/or anchor blocks are characterized by one or more of the following characteristics: (A) The module comprises (1) a back support, (2) a front support, (3) an absorbent layer between the front support and the back support, and (4) a frame that surrounds the rear and front supports and the absorbent layer, the frame comprising four straight-sided segments joined in a rectangular configuration by four corner connectors; (B) Blocks of cross anchor to assemble and maintain a plurality of framed modules in a matrix and to secure the matrix to a support, eg a roof or concrete pillar; (C) separate structural backsheet that can be integrated with a box of junction and electrical terminal function; (D) Hollow or solid ribs on separate structural backsheet; (E) Backsheet rib pattern that is vertical and/or horizontal and/or wave and/or oblique and/or grid; (F) Separate structural backsheet laminated to the solar cell matrix panel; (G) Mounting requires sliding the solar cell matrix panel onto one or more frame rails; (H) The frame rail comprises a channel for engaging the structural backsheet; ( I) The cross anchor block comprises a snap fit to engage and hold the module and/or a step that creates a space between the PV module and support, eg roof, concrete pillar, etc. (J) Integration of pressure adjustments of corner connectors and cross anchor blocks with the electrical terminal function to plug and run the PV modules to provide the electrical connection between the modules, for example, by pushing down on the PV module in the cross anchor block, an electrical connection is created so that the current can move from one module to another; e(K) The plastic in the frame is thermoplastic or thermoset, and has a Young's modulus of 1.5 MPa to 30 MPa.
[0099] Figures 5A-D illustrate this embodiment of the invention. As a first step, the solar cell panel is constructed by laminating a sheet comprising an array of solar cells to a structural back sheet. In one embodiment, the structural backsheet comprises ribs or reinforcing structures (not shown) to impart strength to the solar cell sheet to which it is laminated. Figure 5A shows the insertion of laminated solar cell panel 63 into straight side frame segments 64A and 64B. The laminated solar cell panel can, depending on the lamination process and the size and shape of the solar cell panel and structural sheet, have single or double (or more) edges. In Figures 5A and 5B the laminated solar cell panel 63 is shown with a double edge and as such straight sided frame segments 64A and 64B comprise double channels 65A and 65B for engaging and securing the edges of the laminated solar cell panel 63. Since side frame segments 64A and 64B are attached to the side edges of panel 63, then side frame segments 66A and 66B are attached to panel 63 (Figure 5C). Side frame segments 66A and 66B are structurally the same as side frame segments 64A and 64B except less in length, although in one embodiment, not shown, they are of equal length and are joined in the shape of a square. Before side frame segments 66A and 66B are attached to panel 63, each is first equipped with corner connectors 67A-D. These connectors are sized and molded to comfortably engage and secure the ends of the side frame segments. Once the corner connectors are attached to the frame segments, then these assemblies (eg 68 in Figure 5D) are press-fitted to the panel and side frame segments to form the panel into frame 69 (Figure 5C). Side frame segments can be solid or hollow and, if hollow, can be empty or full. In a preferred embodiment, the side frame segments are hollow and filled with a solid, rigid foam (high modulus) (not shown). The foam insert lends rigidity to the frame, increasing the frame's rigidity to weight ratio and this in turn allows the use of a smaller frame which in turn simplifies handling and installation.
[00100] One embodiment of corner connectors is more fully described in Figures 5E-G. Figures 5E-F illustrate inside and outside views, respectively, of a corner connector 67A. Corner connector 67A comprises three main sections, a first arm 71A, a second arm 71B, and a central body 71C with the two arms extending from the body. Each arm is sized and shaped to securely engage and secure an end of a side or edge frame, and comprises a shelf 72A or 72B, respectively, on which the lower surface of the structural backsheet can rest. The central body 71C comprises channels 73A and 73B for engaging and securing that portion of the solar panel and structural backsheet not already engaged with corresponding channels in the side and edge frames. Outside the central body 71C are positioned insert tabs 74A and 74B for engaging cross anchor blocks which are described in Figures 5H-J. Corner connectors typically comprise a single piece of molded plastic, and in general all corner connectors in a solar panel array are the same in composition and structure. Like straight-sided frame segments, corner connectors can be solid or hollow and, if hollow, can be empty or full. In a preferred embodiment, the corner connectors are hollow and filled with a solid, rigid foam (high modulus) (not shown). The foam insert provides stiffness to the connectors by increasing their stiffness to weight ratio and these, in turn, allow the use of smaller connectors which, in turn, simplify handling and installation.
[00101] Figure 5G provides a cross-sectional view of a corner connector engaged with an edge frame and laminated solar panel. In this view, solar cell matrix panel 75 is laminated to structural backsheet 76 comprising ribs 77A-B. The laminated solar panel is held within channels of frame 78 which end thereof and the end of the laminated solar panel are held within corresponding channels of central body 71C.
[00102] Figures 5H-J illustrate the portion of a solar panel array of this modality for a roof or similar structure. In Figure 5H, the anchor block 79 is engaged with the corner connector 67B of the solar panel 69. The anchor block 70 has the general shape of a cross on each arm of which it comprises a cavity (eg 81) sized and molded to receive and securely hold an insertion tab (eg 74A) from the center body of a corner connector. As illustrated in Figure 5H, the flap and cavity are generally shaped like a trapezoid with the widest section against an arm of the cross to inhibit disengagement of the corner connector from the anchor block without lifting the first off the last. The cavities in the anchor block to receive the insert tabs are positioned over the block so that a space is created under the solar panel and the surface on which it is mounted to allow airflow under the panel and thus promote heat transfer from the panel to the environment.
[00103] When installing a solar panel array on a roof or other surface, first the anchor blocks are arranged in the desired pattern (eg Figure 5I), and then the solar panel assembly is simply pressed into place by positioning from each corner of the panel into an anchor block, and the pressure applied at each corner of the panel engages the panel in the block receiving quadrant (Figure 5J). Although a typical solar panel array takes the form of a standard grid, the array can take on any desired configuration, eg triangular, diamond, circular, etc. Fourth Modality: PV Module Frame
[00104] In an embodiment of the invention, the PV module comprises an angle corner connector. This connector imparts good strength and rigidity and a clean look to the PV module while ensuring easy module assembly.
[00105] This modality is illustrated in Figures 6A-I. Figure 6A shows the front side of the PV module 82A comprising frame sections 83A-D and solar cell array 84. Figure 6B shows the rear side of the PV module 82B comprising frame sections 83A-D and corner connectors 85A - D.
[00106] All corner connectors of any given PV module are essentially equal in size, shape and function. As shown in Figures 6C-D, the corner connector, eg 85A, is L-shaped with first and second legs 86A-B joined by right angle sections 87A-B. On the outer surface of each leg (Figure 6C ) a tab (88A, 88B) is shaped or otherwise loaded to join the connector to a frame section. As shown in Figure 6C, the tabs are I-shaped although other tab shapes, eg cross (+), plus/minus sign (±), can also be employed. The tab crossbars are spaced beyond the leg of the connector on which it is carried, and the tab is usually and preferably smaller in size than the leg on which it is carried.
[00107] The tabs on the connectors are sized and molded to be received and held by a section of the frame. Each frame section has two slits or other openings (one at each end) that correspond in size and shape with a connector tab (eg Figure 6E, slit 88C) with the slit length greater than the slit length in the end. to allow the tab to insert into the gap to be moved in a downward direction so that the tab crossbars are no longer in alignment with the gap crossbars. The tabs on each connector can be the same size and shape, or a different size and/or shape, usually and preferably the same size and shape.
[00108] Figures 6F-H illustrate the way in which the corner connectors couple or join two sections of the PV module frame. Figure 6F shows that the tab is inserted into a corresponding slit, and Figure 6G shows that the tab is then slid from the slit so that the tab crossbars do not line up with the tab crossbars in order to lock the tab in the place against the frame. This procedure is repeated with a frame section to be joined to the frame section to which the connector is already attached to form the connection of the two frame sections at a PV module corner as shown in Figure 6H.
[00109] Since the PV module corner is formed by joining two frame sections, eg 83B and 83C, with a corner connector (within frames 83B and 83C and therefore not shown), and usually after the PV module solar array panel and structural backsheet, if any, are inserted into the frame, the outer sides of the corner seams are welded together using laser 89 or similar tool (figure 6I). Fifth Modality: PV Module Frame
[00110] In an embodiment of the invention, the PV module comprises a frame structure with hinge and snapping features. The module is characterized by (i) a mold part frame with an integrated hinge frame cover, (ii) an edge step on the frame edges to support a solar cell matrix panel, (iii) snap-on cover and (iv) a junction box integrated into one edge of the frame. The hinged frame cover snaps onto the bottom of the frame, can be single or multi-threaded, and if single, ie a single molded part, then it can also be molded with the frame or separate from the frame. The design of this modality can result in better bending strength than multi-part structures, reduced complexity and assembly time, reduced manufacturing costs compared to separate cover and frame fabrication, and helps to secure the solar panel array to the frame. .
[00111] Figures 7A-B illustrate an integrated PV module of this embodiment having a hinge and snap construction. Figure 7A shows assembled (closed) PV module 91A comprising solar cell matrix panel 84. Hinge top frame covers 92A-D are closed at bottoms 93-D (93A and 93C not shown). Figure 7B shows the disassembled (open) PV module 91B with open 92A-D top frame covers, 94A-D hinge assemblies, and 93A-D frame bottoms (93A and 93C not shown).
[00112] Figures 7C-D are examples of a frame/cover fitting modality. Figure 7 shows a frame cover/frame bottom assembly. The 92A frame cover is equipped with 95A plunger which is equipped with 96A fingers. Plunger 95A is sized, molded and placed in frame cover 92A so that it can enter well 97A and fingers 96A can engage fingers 98A which are located within well 97A. Fingers 96A and 98A are molded, sized and placed in plunger 95A and well 97A, respectively, so that when frame cover 92A is closed over bottom of frame 93A, fingers interlock to hold plunger 95A firmly within the well. 97A. The lower part of the frame 93A comprises a shelf or parapet 99A on which a solar cell matrix panel edge 84 can rest, and the cover of the frame 92A is long enough that when closed over the lower part of the frame 93A, it (frame cover 92A) extends over the edge of the solar cell array panel 84 resting on shelf 99A. The cover of frame 92A is attached to the underside of frame 93A by hinge 94A. Figure 7D shows the construction of the frame cover 92A/bottom frame 93A in an assembled or closed state.
[00113] Figures 7E-F show an alternative embodiment of Figures 7C-D. In this alternative embodiment, fingers 96A on plunger 95A are replaced with plunger head 96B on plunger 95B. The shape of well 97A is changed to well 97B which is sized, molded and located at the bottom of frame 93B to accept and hold the head of plunger 96B. Alternative plunger and well shapes can be used in the practice of this invention.
[00114] Mounting the PV 91A module is quick and easy. Bottom frames 93A-D can be molded as a single, integrated piece or as separate pieces assembled into the desired configuration in any convenient manner such as those described elsewhere in this specification. The 92A-D frame covers can also be molded as part of a single construction integrated with the 93A-D frame bottoms (a preferred construction with the hinged frame covers for the frame bottom), or the frame covers can be molded into separate pieces that are attached separately during the construction process (in this modality the hinges are not part of the construction). Mounting is simply by placing a frame-sized solar cell array panel on the bottom of the frame so that each edge of the panel rests on a corresponding frame edge and then closing the frame covers over those frame edges. that the plunger enters and engages its corresponding well. In one embodiment of this invention, one or more of the lower portions of frame 93A-D comprise an integrated junction box as described in this specification. Sixth Modality: PV Module Frame
[00115] In an embodiment of the invention, the PV module is manufactured by a blow molding process. This process allows the fabrication of hollow parts with complex shapes, allows the integration of structural backsheets and junction boxes, and provides a high stiffness-to-weight ratio (which will reduce the weight and therefore module costs).
[00116] The process of this modality comprises the steps of filling a thermoplastic olefin (TPO) with long glass fiber to produce a composite of high rigidity, low shrinkage. The TPO composite is combined with additives including, but not limited to, UV stabilizers, pigments or dyes, antioxidants and nucleating agents. The TPO composite can also contain filler that emits energy through radiation to ensure that the PV module emits heat during operation, thus maximizing cell efficiency. These cooling particles can comprise silicon carbide, silicon dioxide and the like.
[00117] The TPO composite is extruded using conventional blow molding equipment and conditions to produce an integrated frame and backsheet as described in Figures 8A-C. The solar cell matrix panel is then inserted into the frame, and an elastomeric sealant is applied to ensure a waterproof system.
[00118] Figure 8A shows the front side of the PV module comprising the hollow blow molded plastic frame 102 in which the solar cell matrix panel 84 rests. The panel is sealed in place over the frame with an elastomeric sealant (not shown) which is applied over the seam formed by the edges of the panel and frame.
[00119] Figure 8B shows the rear part of the PV module 101 comprising plastic frame 102 with integrated back sheet 103 and integrated junction box 105 with integrated junction box cover 106. The back sheet comprises ribs of integral length 104A and ribs of integrated width 104B. As used herein, "integrated" means that all components, i.e. frame, ribbed backsheet, junction box and cover, are part of a single article, molded as opposed to separate pieces attached to each other.
[00120] Figure 8C shows a cross section of the PV module of Figure 8A. As can be seen from this figure, the plastic frame 102, and the length and width of ribs 104A and 104B, respectively, are hollow. Injection Molding Process to Produce an Over-Mold Frame
[00121] In an embodiment of the invention, the PV module is produced using an over-molding process. The process is one-step and produces a frame with better sealing performance. The PV module, frame and/or process are characterized by one or more of the following features: (A) The module comprises (1) a back support, (2) a front support, (3) an absorbent layer between the front support and the rear support, and (4) an integrated frame surrounding the rear and front supports and the absorbent layer such that the frame is integrated with (i) the rear support; and (ii) an interlayer between the integrated frame and the lamination; (B) The frame is prepared through a one-step over-molding process; (C) The frame is a single, integrated molded part and therefore simplifies the module assembly; (D) The frame is integrated with a back sheet of structural plastic; (E) The frame is integrated with the junction box and/or electrical terminal box; (F) The frame is integrated with the cover of the junction box; (G) The frame does not require adhesive to seal its edges and therefore provides a better seal for the module cell; (H) The interlayer is thermoplastic or thermoset and has a certain coefficient of linear thermal expansion (CLTE ) which corresponds with the excess molding material and laminating material; (I) The interlayer is laminated with the front support and the absorbent layer, or is bonded with the front support and the absorbent layer by an adhesive; and/or(J) The plastic in the frame is thermoplastic or thermoset, and has a Young's modulus of 1.5 MPa to 30 MPa.
[00122] Figures 9A-F describe an embodiment of this invention. Figure 9A shows solar cell matrix panel 84. This panel may comprise one or a plurality of solar cells, and may be a mono- or multi-layer construction. Figure 9B shows finished module 107 comprising panel 84 overmolded with plastic frame 108.
[00123] Figure 9C shows solar cell panel 84 within molded bottom 109, and Figure 9D shows the in-mold panel of Figure 9C with mold cap 111 in place to cover panel 84. Figure 9E shows the mold Figure 9D closed after the plastic has been injected to form the overmolded plastic frame 108. Figure 9F is an exploded view showing the finished product 107 removed from the mold from the mold cap 111 and mold bottom 109. Seventh Modality: PV Module Frame
[00124] In an embodiment of the invention, the PV module mounting bracket is integrated in the module itself. This design results in installation cost and time savings.
[00125] Figures 10A-F show several variations on a PV module with an integrated bracket. Figure 10A shows module 112 with extended support legs 113A-D attached to frame 115 by hinges 114A-D, respectively. Support legs 113A-B are longer than support legs 113C-D to provide a tilt to module 112 to optimize its exposure to the sun. The difference in length between legs 113A-B and 113C-D can vary widely. The hinges have a releasable locking feature (not shown) to hold the stand legs in their extended or folded position, but which can be released when the legs are moved from one position to another. Arrows 116A-D show the direction in which the legs are moved to fold them at the rear of module 112, and Figure 10B shows the module with the legs bent at its rear side. The module configuration in Figure 10B lends itself to storage and transport, and the swivel nature legs facilitate installation on a roof or pillar.
[00126] Figures 10C-E show another variation of this modality. Figures 10C-D show support legs 113A-D bent into channels 117A-D, respectively, of frame 115 opposite out of frame 115 and against the rear of module 112. Figure 10E shows the extended legs locked in place with side arms 118B and 118D (side arms A and C not shown). The legs and side arms are equipped with hinges (not shown) to allow the legs to be folded into the frame channels.
[00127] Figure 10F shows another variation in which the rear support legs 113A-B are telescopic in construction to allow adjustment to their respective heights. The legs of this design are equipped with 119A-B means, respectively, to lock the legs to a desired height. These means include, but are not limited to, pressure sleeves, pins and holes, and various constriction constructions, eg torsion rings.Eighth Modality: PV Module Frame
[00128] In one embodiment of the invention, the PV module is characterized by an integrated one-piece frame with a lockable entry on one edge through which a solar panel assembly can be inserted. The frame provides four-edge support for mounting, and the inlet port through which the mount is inserted into the frame can be closed and sealed, usually with a snap-on cap.
[00129] The PV module is characterized by one or more of the following features: (A) A solar panel assembly comprising a back support, a front support and an absorbent layer between the front support and the rear support with a frame surrounding the assembly ;(B) One-piece molded frame;(C) A junction box integrated into the frame;(D) An entry at one end of the frame through which the assembly can be inserted into the frame;(E) The frame entry can be closed with a block of or seal cap with a snap-on closure, and the cap can be hinged to the frame or detachable from the frame; e(F) A sealing position between the closed frame cover and the inserted mount, sufficient sealant normally applied after the mount has been inserted into the frame and before the cover is closed.
[00130] Sufficient sealant is applied to securely close the cover over the inserted assembly. In one embodiment, the sealant also serves as an adhesive between the upper and lower portions of the frame. The composition of the sealant is not critical to the practice of this invention.
[00131] The composition of the frame can also vary for convenience, and can be thermoplastic or thermoset material. Typically, the material from which the frame is formulated has a Young's modulus of 1.5 MPa to 30 MPa, and the modulus can be reinforced by including fiber (eg, glass fiber, carbon fiber, etc.) in the formulation. The composition can be enhanced with various additives such as antioxidants, UV stabilizers, pigments, dyes, nucleating agents, flame retardants, and the like. The composition can also have one or more fillers to ensure the module emits heat during operation and maximizes cell efficiency. These fillers include silicon carbide, silicon dioxide, boron nitride, and the like.
[00132] With the molded part design, the PV module frame of this modality provides good bending/bending resistance and reduces module mounting with the integrated junction box and easy insertion of the solar panel mounting.
[00133] Figure 11A is an exploded view of a PV module assembly of this embodiment of the invention. The PV 120 module frame is a single, integrated molded piece comprising the integrated junction box 121, strip 122 and input port 123. The strip 122 and input port 123 are sized and molded to receive and secure the solar panel assembly 124. In the PV module assembly, the solar panel assembly 124 is inserted as indicated by the movement arrows 125 into and through the input port 123 so that the panel edges engage and are held by the strip 122. the assembly is inside the frame, then a sealant (not shown) is applied over the inlet port and seal block (or cover) is inserted as indicated by movement arrows 126. The assembled PV module 127 is shown in Figure 11B.
[00134] Figure 11C illustrates the sealing block inserted into the frame, and the solar panel assembly. The solar panel assembly 124 comprises front or top bracket 124A, rear or bottom bracket 124B, and absorbent panel (i.e., solar cell array) 124C. The mount snugly fits into and is carried by strap 122, which is defined by upper and lower strap surfaces 122A and 122B, respectively. Strip surfaces 122S-B are sized and molded to securely engage the seal block 125 with a sealant snap fastener 129 positioned between the outer edges of the assembly 124 and seal block 125. Ninth Modality: PV Module
[00135] In an embodiment of the invention, the PV module is characterized by a back panel comprising a bottom skin and a plurality of spaced support legs. The legs are attached to the bottom surface of the photovoltaic laminate in a way that creates open channels or chimneys that help cool the PV module. Figure 12 shows an example of the back panel.
[00136] The PV module is characterized by one or more of the following features: (A) The back panel comprises a bottom skin and a plurality of spaced support legs. Typically, the back panel is a single integrated molded plastic piece. The back panel is attached to the PV laminate by adhering, eg gluing, the legs to the bottom surface of the photovoltaic laminate.(B) The back panel is normally prepared with fiber reinforced polymer. The fiber can be glass fiber, carbon fiber, basalt fiber, Kevlar fiber, high strength polymeric fibers in roving, carpet or fabric braids and/or a combination of two or more of these. The underside skin can be designed to give maximum rigidity and strength with optimal material use. For example, the outer layer of the underside skin can be prepared with fiber mat or woven fiber reinforced polymer.(C) The back panel can be prepared by an extrusion process. If a continuous fiber or fiber mat is incorporated in the back panel, then it can also be prepared by pultrusion.(D) The channels or chimneys formed by the bundle panel accessory for the photovoltaic laminate act as openings that can remove heat from the module photovoltaic, typically more efficiently than conventional PV module constructions. With the ability to operate at lower temperatures, the PV module can produce electrical power more efficiently.(E) The channel on one edge of the module can hold a small, thin junction box, and the edge leg can be machined to prepare holes to allow electrical or other cables to pass through the edge leg for connection to the junction box or other PV module structure.(F) The skin of some channels may be thicker than others to allow preparation of holes or locking mechanisms for the purpose of securing the module.(G) The rear panel can be prepared strong enough to reduce or eliminate the use of support in some applications, and/or reduce the thickness of the front glass plate.(H) The width of the individual rear panel channels may vary. For example, smaller width channels can be used on the module edges to increase support for the PV laminate edges, while larger width channels can be used inside to increase ventilation capacity.
[00137] Figure 12 illustrates an exploded view of a PV module of this modality. The back panel 130 comprises a back skin 132 with a plurality of integral legs 131 spaced apart to form a plurality of channels or chimneys 133. The legs 131 are normally and preferably of the same size (height, length and thickness) and shape, but their number may vary for convenience. The spacing of the legs from each other may also vary and therefore the size of the channels may vary from one another. The back panel 131 is attached to the PV 134 laminate by any convenient method, generally by applying an adhesive to the top of each leg and then contacting the legs with the PV under sufficient temperature and pressure and for a sufficient length of time to allow for the adhesive to cure. Lamination Process
[00138] In an embodiment of the invention, multiple layers of PV module are laminated to an integrated frame and structural backsheet in a single step. The multiple layers of PV module comprise an upper transparent polymer or glass layer, an encapsulated layer, and a silicone layer. The encapsulated layer typically comprises a polymer such as ethylene vinyl acetate (EVA). Lamination is carried out in a laminating device and under pressure or vacuum conditions. After lamination an adhesive, eg silicone rubber, is applied to seal the edges of the solar cell layers.
[00139] Multiple PV module encapsulant processing includes the steps of placing a sheet of material on the glass, and then placing in the same pre-rated and connected solar cells. Another layer of sheet encapsulant is then placed on top of this, followed by a final structural back sheet integrated with a module frame at the rear of the solar panel. The finished laminate is then placed in a rolling mill machine, which is heated to an ideal temperature to melt the encapsulating material. In one embodiment, excessive pressure is applied to the laminate to facilitate the lamination process. In one embodiment, a vacuum is then applied to remove any trapped air bubbles during the heating process, resulting in a sealed solar cell array that is bonded to a glass surface. This process laminates the framed structural backsheet to the cell layers together to shorten the cycle time of the module assembly process.
[00140] The resulting laminated product exhibits improved flexural strength compared to conventionally prepared PV products. This one-step process joining the PV lamination to the frame reduces the assembly process of the finished product, ie, the PV module. With the inclusion of the ribs on the backsheet, the PV module features desirable flex and torsional stiffness and strength. In a preferred embodiment, a junction box is integrated into the backsheet structure.EXAMPLESRaw materials
[00141] Table 1 reports the materials used in these examples.
YUPLENETM SK B391G is a propylene impact copolymer for injection molding. ACOPLAM 8200 is an ethylene/1-octene elastomer having a density of 0.87 g/cm3 and an I2 of 5. System FR 50A-2 is a blend of ammonium polyphosphate and pentaerythritol used as flame retardant. Cabot PLASBLAKTM UN2014 is a standard batch of polyethylene filled with 50% by weight of carbon black.IRGANOX 1010 is Pentaerythritol tetrakis(3-(3,5-di-tert-butyl) - 4-hydroxyphenyl) propionate), a high molecular weight phenolic antioxidant with low volatility. IRGANOX MD 1024 is 2',3-bis[[3-[3,5-di-tert-butyl-4-hydroxyphenyl]propionyl] ] propioniohydrazine.DSTDP is distearylthiodipropionate, stearyl 3,3'-thiodipropionate.CYASORBA UV-3529 is a UV stabilizer, 1,6-hexanediamine,N1,N6-bis(2,2,6,6-tetramethyl-4-piperidinyl) , polymers with morpholine-2,4,6-trichloro-1,3,5-triazine, methylated reaction products (CAS NO.193098-40-7).DPO-BSA/1010 (Azide) is a mixture of 4, 4'-oxybisbenzenesulfonyl azide and IRG ANOX 1010. Combination Process Preparation of the FR Standard Batch
[00142] FR Additive, Antioxidant, UV Stabilizer, Color Standard Lot, ENGAGE 8200 and SK B391G are pre-mixed in a high speed mixer at 900 revolutions per minute (rpm) for 3 minutes. The mixture is fed into the main feed port of a ZSK40 extruder (L/D=48). The screw speed is set at 250 rpm, and the drum temperature is 190-200°C. The feed rate is 30 kilograms per hour (kg/h). Nitrogen inlet is used in the second zone to protect material during blending. Vacuum is opened to remove volatile compounds. The strands are cooled by water, then cut into pellets. Standard Fiberglass/IPP Batch Preparation
[00143] The PP resin and the coupling agent DPO-bisulfonyl azide at 400~800 ppm) and fiberglass with weight ratio 50:50 are fed into the main port of the ZSK40 extruder (L/D=48) according to the formulation. Fiberglass is fed into the vent port in zone 5. The screw speed is set at 250 rpm, and the drum temperature at 190-200°C. The feed rate is 40 kg/h. Vacuum is opened to remove volatile compounds. The strands are cooled by water, then cut into pellets. Injection Molding
[00144] Pellets of standard batch IPP reinforced with GF and standard batch FR with in a 50:50 weight ratio are fed into an injection molding apparatus. The drum temperature is set at 70°C, 190°C, 200°C, 200°C, and 200°C. The mold temperature is 30°C. ASTM standard test samples for mechanical, electrical and FR testing are injection molded on a FANUC machine. Mechanical Performance
[00145] The tensile strength and flexural strength tests are conducted by an INSTRON 5565 according to ASTM D638.
[00146] The Izod impact strength test is performed on a CEIST 6960 in accordance with ASTM D256.
[00147] UL94
[00148] The UL94 vertical flammability test is performed by a UL94 chamber per ASTM D 3801.
[00149] UV exposure
[00150] The 1000 hour UV exposure is conducted by a Q-lab QUV according to IEC61215.
[00151] Results
[00152] Table 2 reports the performance for different glass fiber reinforced IPP composites. The addition of the 50A-2 Intumescent FR System dramatically improves FR performance. With 20% 50A-2 (Invention Example 1), the composite can achieve UL94 V-0 (3.2 mm), and shows a good balance for mechanical performance and weather resistance compared to Comparative Example 1. With 25% 50A-2 (Example of Invention 1), the composite can achieve UL94 V-0 (1.6 mm). In contrast, at 40% Mg(OH)2 (Comparative Example 2) the composite fails the UL94 V-0(3.2mm) test.

权利要求:
Claims (8)
[0001]
1. Solar panel assembly, characterized in that it comprises a: (A) PV module (54) comprising one or more PV cells within a plastic frame, and the frame comprising plastic front base connections (35A, 35B) and rear base (35C, 35D), front base connections (35A, 35B) pivotally connected to PV module frame (54) and rear base connections (35C, 35D) slidably engaged with PV module frame (54 ); (B) Plastic base comprising two separate mounting bases (38A, 38B) joined by a connector plate (39), each mounting base (38A, 38B) equipped with plastic front pins (45A, 45B) for pivotally engaging the front base connections (35C, 35D) of the PV module frame (54), and rear couplings (47B) engaged in a mating relationship with the rear base connections (35C, 35D) of the PV module (54);( C) Plastic wind deflector (36) engaged in mating relationship with each of the two rear base attachments (35C, 35 D);(D) Plastic junction box (56A-56D) integral with PV module frame (54); and(E) Two plastic self-aligning devices (57A-57D) for joining adjacent PV modules (54) to each other, each device (57A-57D) integral with the PV module frame (54).
[0002]
2. Solar panel assembly according to claim 1, characterized in that the junction box (56A-56D) comprises a first part that is integral with one of the self-alignment devices (57A-57D) and a second part that it is integral with other self-aligning devices (57A-57D).
[0003]
3. Solar panel assembly according to claim 1, characterized in that the junction box (56A-56D) is separate from the self-alignment devices (57A-57D).
[0004]
4. Solar panel assembly according to claim 1, characterized in that one or more of (1) the PV cell frame, (2) the plastic base, (3) the plastic wind deflector (36) , (4) the plastic junction box (56A-56D), e5. ) the plastic self-aligning devices (57A-57D) are made of a composition comprising: (A) a thermoplastic polymer, (B) a reinforcing element; (C) a non-halogen intumescent flame retardant; (D) an impact modifier; (E) a coupling agent and optionally (F) one or more additives.
[0005]
5. Solar panel assembly according to claim 4, characterized in that the composition comprises, based on the weight of the composition, (A) 10-80% by weight of a thermoplastic polymer, (B) 10-55% by weight of a reinforcing element, (C) 1-30% by weight of a non-halogen intumescent flame retardant, (D) 1-20% by weight of an impact modifier, (E) 0.001-0.5% by weight of a coupling agent and optionally (F) one or more additives.
[0006]
6. Solar panel assembly, according to any one of claims 4 or 5, characterized in that the thermoplastic polymer is an impact-modified polypropylene, the reinforcement element is fiberglass, the intumescent flame retardant not containing halogen is a compound based on organic phosphorus, the impact modifier is a polyolefin elastomer in addition to the IPP of (A), and the coupling agent is a bis(sulfonyl azide).
[0007]
7. Solar panel assembly according to claim 1, characterized in that the plastic PV module frame (54) has (A) a molded unitary part or an over-molded part, (B) an L-shape ( 55), (C) a two-part junction box (56A-56D) with one piece located on one side of the frame and the other piece located opposite and on the other side of the frame; (D) a self-aligning device (57A-57D), and (E) at least one structural member (58A-58B) on the back of the panel (31) to provide mechanical strength to the panel (31).
[0008]
8. Solar panel assembly according to claim 1, in which the PV module (54) is characterized in that it comprises: (A) a rear support (124B), a front support (124A) and an absorbent layer ( 124C) between the front support (124A) and the rear support (124B); (B) An integrated one-piece frame molded (120) around the module (54); (C) an integrated junction box (121) in the frame (120); (D) an inlet (123) on one end of the frame (120) through which the module (54) can be inserted into the frame (120); (E) a sealing block (125) or cap over inlet (123) and engaged with frame (120) in mating relationship; and (F) a sealing position (129) between the frame cover (120) and the inserted module (54).

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同族专利:

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公开号 | 公开日

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CN105308115B|2018-06-12|

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ES2838273T3|2021-07-01|

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EP3013901B1|2020-11-04|

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WO2014205802A1|2014-12-31|

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KR20160037889A|2016-04-06|

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BR112015031282A2|2017-07-25|

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JP6346946B2|2018-06-20|

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EP3013901A4|2017-02-08|

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JP2016530347A|2016-09-29|

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EP3013901A1|2016-05-04|

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CN105308115A|2016-02-03|

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KR102072507B1|2020-02-03|

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US20160134231A1|2016-05-12|

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法律状态:
2018-03-06| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2018-03-13| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2018-03-20| B06I| Publication of requirement cancelled [chapter 6.9 patent gazette]|Free format text: ANULADA A PUBLICACAO CODIGO 6.6.1 NA RPI NO 2462 DE 13/03/2018 POR TER SIDO INDEVIDA. |

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2018-03-27| B15K| Others concerning applications: alteration of classification|Ipc: C08L 23/10 (2006.01), H02S 20/30 (2014.01), H01L 3 |

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2020-01-07| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

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2021-03-02| B06A| Patent application procedure suspended [chapter 6.1 patent gazette]|

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2021-06-08| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2021-07-20| B350| Update of information on the portal [chapter 15.35 patent gazette]|

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2021-08-24| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 28/06/2013, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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申请号 | 申请日 | 专利标题

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PCT/CN2013/078421|WO2014205802A1|2013-06-28|2013-06-28|Plastic photovoltaic module frame and rack, and composition for making the same|

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