CN111452397B - Mass production preparation method of composite material part containing solar cell thin film - Google Patents
Mass production preparation method of composite material part containing solar cell thin film Download PDFInfo
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- CN111452397B CN111452397B CN202010306217.0A CN202010306217A CN111452397B CN 111452397 B CN111452397 B CN 111452397B CN 202010306217 A CN202010306217 A CN 202010306217A CN 111452397 B CN111452397 B CN 111452397B
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- solar cell
- composite material
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- thin film
- fiber
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- 239000002131 composite material Substances 0.000 title claims abstract description 39
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 27
- 238000002360 preparation method Methods 0.000 title claims abstract description 13
- 239000010409 thin film Substances 0.000 title claims description 24
- 239000000463 material Substances 0.000 claims abstract description 47
- 239000000835 fiber Substances 0.000 claims abstract description 40
- 239000011347 resin Substances 0.000 claims abstract description 27
- 229920005989 resin Polymers 0.000 claims abstract description 27
- 238000000034 method Methods 0.000 claims abstract description 17
- 238000002347 injection Methods 0.000 claims abstract description 15
- 239000007924 injection Substances 0.000 claims abstract description 15
- 230000008569 process Effects 0.000 claims abstract description 10
- 238000001721 transfer moulding Methods 0.000 claims abstract description 5
- 239000004744 fabric Substances 0.000 claims description 23
- 239000010408 film Substances 0.000 claims description 20
- 238000005520 cutting process Methods 0.000 claims description 8
- 229910001218 Gallium arsenide Inorganic materials 0.000 claims description 7
- JBRZTFJDHDCESZ-UHFFFAOYSA-N AsGa Chemical compound [As]#[Ga] JBRZTFJDHDCESZ-UHFFFAOYSA-N 0.000 claims description 6
- 229920000049 Carbon (fiber) Polymers 0.000 claims description 4
- 239000004917 carbon fiber Substances 0.000 claims description 4
- 239000003365 glass fiber Substances 0.000 claims description 4
- 239000010410 layer Substances 0.000 claims description 4
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims description 4
- 239000002759 woven fabric Substances 0.000 claims description 4
- 239000003822 epoxy resin Substances 0.000 claims description 3
- 238000010438 heat treatment Methods 0.000 claims description 3
- 238000002844 melting Methods 0.000 claims description 3
- 230000008018 melting Effects 0.000 claims description 3
- 229920000647 polyepoxide Polymers 0.000 claims description 3
- 239000000843 powder Substances 0.000 claims description 3
- 239000011241 protective layer Substances 0.000 claims description 3
- 238000004321 preservation Methods 0.000 claims description 2
- 230000000694 effects Effects 0.000 abstract description 4
- 238000000465 moulding Methods 0.000 abstract description 2
- 210000004027 cell Anatomy 0.000 description 37
- 238000009745 resin transfer moulding Methods 0.000 description 6
- 238000003825 pressing Methods 0.000 description 5
- 239000003795 chemical substances by application Substances 0.000 description 4
- 238000003892 spreading Methods 0.000 description 4
- 230000007480 spreading Effects 0.000 description 4
- 238000009966 trimming Methods 0.000 description 4
- 210000000170 cell membrane Anatomy 0.000 description 3
- 238000009940 knitting Methods 0.000 description 3
- 238000006243 chemical reaction Methods 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 229910021419 crystalline silicon Inorganic materials 0.000 description 2
- 238000005034 decoration Methods 0.000 description 2
- 239000011521 glass Substances 0.000 description 2
- 229920006253 high performance fiber Polymers 0.000 description 2
- 238000010030 laminating Methods 0.000 description 2
- 230000001603 reducing effect Effects 0.000 description 2
- 238000004904 shortening Methods 0.000 description 2
- 238000001228 spectrum Methods 0.000 description 2
- 239000002966 varnish Substances 0.000 description 2
- 239000013585 weight reducing agent Substances 0.000 description 2
- 238000010521 absorption reaction Methods 0.000 description 1
- 238000004378 air conditioning Methods 0.000 description 1
- 210000005056 cell body Anatomy 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 239000000805 composite resin Substances 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000012761 high-performance material Substances 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000011031 large-scale manufacturing process Methods 0.000 description 1
- 239000003562 lightweight material Substances 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
- B29C70/74—Moulding material on a relatively small portion of the preformed part, e.g. outsert moulding
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/048—Encapsulation of modules
- H01L31/0481—Encapsulation of modules characterised by the composition of the encapsulation material
-
- 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
Abstract
The invention discloses a mass production preparation method of a composite material part containing a solar cell film, and belongs to the technical field of new energy automobiles. The component structure comprises the flexible solar cell film component and the high-performance continuous fiber composite material, and the flexible solar cell film component and the high-performance continuous fiber composite material are integrally formed by adopting an RTM (resin transfer molding) process in a mode of injecting fast curing resin at higher pressure, so that an automobile applying the product has excellent cruising and improving effects, and the light and high-strength material characteristics of the high-performance continuous fiber composite material are fully exerted; the preparation process adopts higher injection pressure and molding pressure, so that the rapid production takt time of the whole part is less than or equal to 10min, the appearance quality is improved, the yield is improved, and the production and manufacturing cost is reduced.
Description
Technical Field
The invention belongs to the technical field of new energy automobiles, and particularly relates to a mass production preparation method of a composite material part containing a solar cell film.
Background
The photovoltaic industry has developed rapidly in recent years and its applications have been extended into various fields. At present, in the new energy automobile industry, the solar cell film is concerned by more and more automobile manufacturers, the continuous development of the technology can effectively bring considerable improvement to the cruising ability of the new energy electric automobile, and the solar cell film can also be used for air conditioning and power consumption of other equipment in the automobile and prolong the driving mileage of the automobile.
On the other hand, high performance and lightweight materials have become the choice of more and more automobile manufacturers driven by the trend of weight reduction of automobiles. The high-performance fiber resin-based composite material has excellent light weight and high strength, can meet the weight reduction requirement of new energy automobiles, and can meet various physicochemical properties and safety requirements of corresponding automobiles.
In principle, the higher the efficiency ratio of the solar cell is, the lighter the solar cell is, and the better the endurance improving effect brought to the new energy automobile is. The highest recorded energy conversion rate of the flexible gallium arsenide-based double-junction battery piece film in the market at present can be up to 31.6%, but the existing application is on the surface of a glass vehicle body part, such as top cover skylight glass, and compared with a fiber composite material product, the double-junction battery piece film is larger in thickness and heavier in weight; in addition, in the process aspect, the product can not be formed integrally with the solar cell film. In addition, the preparation processes of the fiber composite material product of the integrated solar battery pack are low-efficiency traditional processes with 30min or even longer production tact, such as a prepreg forming process, a VARI liquid forming process or a vacuum bag pressing process, and the like, the forming period is long, and the tact requirement of large-scale production cannot be met; meanwhile, because the forming pressure is limited, the appearance quality and the yield are difficult to ensure, and complicated post-treatment is often needed, and both the appearance quality and the yield result in higher production cost.
Disclosure of Invention
Aiming at the defects of the prior art, the invention provides a mass production preparation method of a high-performance continuous fiber composite material structure containing a high-efficiency solar cell film, which can be quickly formed, by utilizing a high-performance fiber and quick-curing resin system and selecting a quick mass production process.
A mass production preparation method of a composite material part containing a solar cell film comprises a solar cell film component and a high-performance continuous fiber composite material, and the component is integrally formed by injecting a fast curing resin by an RTM (resin transfer molding) process, and specifically comprises the following steps:
step 1, laying fiber fabrics and cutting the fiber fabrics into material blocks;
step 2, arranging the solar cell thin film assembly on the material block in the step 1;
and 3, placing the material block provided with the solar cell thin film assembly in a mold, closing the mold, vacuumizing, injecting a preheated and mixed resin material, standing under the conditions of heat preservation and mold protection after injection, and demolding to obtain the composite material part containing the solar cell thin film.
Further, the solar cell thin film assembly is a flexible gallium arsenide double-junction or multi-junction cell thin film sheet, and the thickness of the flexible gallium arsenide double-junction or multi-junction cell thin film sheet is smaller than 20 mu m.
Furthermore, the high-performance continuous fiber composite material is of a laminated plate structure or a sandwich structure, and the thickness of the composite material is 0.5 mm-20 mm.
Further, the material of the fiber fabric includes, but is not limited to, carbon fiber, glass fiber or mixed fiber, and the fabric is in the form of warp knitting axial fabric or woven fabric.
Further, the temperature of the die in the step 3 is 70-150 ℃.
Further, the resin material is injected in the step 3 by adopting a high pressure or medium pressure mode, wherein the high pressure is 30-150 bar, and the medium pressure is 5-30 bar.
Further, the standing time in the step 3 is less than 6 min.
Further, for the parts with complex structures, the blocks can be preformed before the solar cell thin film assembly is arranged according to actual needs.
Further, after the standing treatment in step 3 is completed, the mold is opened and closed to be in a half-opened state, a surface protective resin material is injected, and the mold is closed and cured, so that a protective layer can be formed on the surface of the component.
Further, the thickness of the protection layer is 100-350 [ mu ] m.
According to the high-performance continuous fiber composite material product containing the solar cell film and capable of being integrally and quickly molded, the flexible solar cell film with high efficiency ratio and the high-performance continuous fiber composite material are combined in the product structure, so that an automobile applying the product has an excellent endurance improving effect, the material characteristics of light weight and high strength of the high-performance continuous fiber composite material are fully exerted, and under the condition that various physical and chemical properties are met, the traditional metal top cover is taken as an example, and the weight reducing effect of more than or equal to 30% can be realized compared with a metal material; the preparation process adopts higher injection pressure and molding pressure, not only realizes the rapid production takt of the whole part to be less than or equal to 10min (without the surface protection layer injection process), but also improves the appearance quality and the yield, thereby reducing the production and manufacturing cost.
Detailed Description
The invention relates to a mass production preparation method of a composite material structure containing a solar cell membrane, which structurally comprises a flexible solar cell membrane component and a high-performance continuous fiber composite material, wherein the flexible solar cell membrane component and the high-performance continuous fiber composite material are integrally formed by adopting an RTM (resin transfer molding) process in a mode of injecting fast curing resin at higher pressure, and the RTM process is well known in the field and is formed by resin transfer molding, and comprises but not limited to HP-RTM, LP-RTM, C-RTM, S-RTM and other similar RTM process forms. The flexible solar cell film is a double-junction or multi-junction gallium arsenide cell, has better solar spectrum matching capability compared with a more common crystalline silicon cell on the market, can absorb short wave bands and long wave bands of a solar spectrum so as to achieve higher photoelectric conversion efficiency, and has the thickness of a cell body of less than 20 mu m, so that the absorption rate can be equal to the crystalline silicon cell with the thickness of more than 150 mu m; the structure of the composite material comprises a laminated plate structure, a sandwich structure and the like, the thickness of the composite material is 0.5-20 mm, fiber high-performance continuous fibers are adopted, the resin is high-performance fast curing resin, the curing time of the resin is less than 6min, and the forming takt time of the whole part is less than or equal to 10 min.
The following examples further illustrate the present invention but are not to be construed as limiting the invention. Modifications or substitutions to methods, procedures, or conditions of the invention may be made without departing from the spirit and scope of the invention.
Example 1
An automobile composite material exterior trimming part comprises a solar cell thin film component and a high-performance continuous fiber composite material;
the solar cell thin film assembly is an assembly comprising a plurality of flexible gallium arsenide double-junction or multi-junction cell thin film sheets, and the thickness of the assembly is less than 20 mu m;
the fiber of the high-fiber composite material is composed of continuous fiber, the material of the continuous fiber includes but is not limited to carbon fiber, glass fiber, mixed fiber and the like, and the fabric form can be warp knitting axial fabric, woven fabric and the like;
the resin used by the composite material is high-performance fast curing epoxy resin;
the composite material structure comprises a laminated plate structure, a sandwich structure and the like, and the thickness of the composite material structure is 0.5 mm-20 mm.
The preparation method comprises the following steps:
s1: preparing materials: arranging the fiber fabric on a material roll;
s2: laminating and cutting: aligning, spreading and stacking the fabric on the material roller on a spreading table, and then cutting the fabric into a material block;
s3: preforming: grabbing the material block to a preheated platform for heating, wherein the temperature reaches the melting temperature of a powder scattering material on a fabric, grabbing the material block to a preforming mold, then closing the mold and performing cold pressing for preforming, grabbing a formed prefabricated body to a preforming tool and cutting the residual edge, and for the external decoration piece with a simple structure, the material block does not need to be preformed, and the solar cell film component is directly placed on the material block;
s4: placing a solar cell film: the solar cell thin film assembly is placed at a set position, and a positioning auxiliary device can be adopted to ensure the accuracy of the position;
s5: medium/high pressure injection: placing a prefabricated body with a solar cell film in a constant-temperature press mold with the temperature of 70-150 ℃, sequentially carrying out mold closing, mold locking and vacuumizing, and injecting resin, a curing agent and an internal release agent which are fully preheated and mixed according to a proportion, wherein the proportion is 100: (10-30): (1-5), the injection pressure can be 30-150 bar at high pressure or 5-30 bar at medium pressure;
s6: and (3) curing: after the injection step is finished, keeping the mold closing, keeping the temperature, and keeping the mold pressing for less than or equal to 6min so as to solidify the injection material in the mold;
s7: taking a workpiece: and cooling and ejecting after the steps are finished, and taking out the finished automobile exterior trimming part product.
The steps can select automatic production to realize manual operation to the maximum extent, thereby shortening the production beat, greatly improving the production efficiency and simultaneously improving the production stability and the product quality. The above-mentioned S1-S7 is the production beat of one piece, and the time is less than or equal to 10 min.
Example 2
An automobile composite material exterior trimming part comprises a solar cell thin film component and a high-performance continuous fiber composite material;
the solar cell thin film assembly is an assembly comprising a plurality of flexible gallium arsenide double-junction or multi-junction cell thin film sheets, and the thickness of the assembly is less than 20 mu m;
the fiber of the high-fiber composite material is composed of continuous fiber, the material of the continuous fiber comprises but is not limited to carbon fiber, glass fiber, mixed fiber and the like, and the fabric form can be warp knitting axial fabric, woven fabric and the like;
the resin used by the composite material is high-performance fast curing epoxy resin, the composite material structure comprises a laminated plate structure, a sandwich structure and the like, and the thickness of the composite material structure is 0.5 mm-20 mm.
The preparation method comprises the following steps:
s1: preparing materials: arranging the fiber fabric on a material roll;
s2: laminating and cutting: aligning, spreading and stacking the fabric on the material roller on a spreading table, and then cutting the fabric into a material block;
s3: preforming: grabbing the material block to a preheated platform for heating, wherein the temperature reaches the melting temperature of a powder scattering material on a fabric, grabbing the material block to a preforming mold, then closing the mold and performing cold pressing for preforming, grabbing a formed prefabricated body to a preforming tool and cutting the residual edge, and for the external decoration piece with a simple structure, the material block does not need to be preformed, and the solar cell film component is directly placed on the material block;
s4: placing a solar cell film: the solar cell thin film assembly is placed at a set position, and a positioning auxiliary device can be adopted to ensure the accuracy of the position;
s5: medium/high pressure injection: placing a prefabricated body with a solar cell film in a constant-temperature press mold with the temperature of 70-150 ℃, sequentially carrying out mold closing, mold locking and vacuumizing, and injecting resin, a curing agent and an internal release agent which are fully preheated and mixed according to a proportion, wherein the proportion is 100: (10-30): (1-5), the injection pressure can be 30-150 bar at high pressure or 5-30 bar at medium pressure;
s6: and (3) curing: after the injection step is finished, keeping the mold closing, keeping the temperature, and keeping the mold pressing for less than or equal to 6min so as to solidify the injection material in the mold;
s7: surface protection layer injection: after the steps are completed, the upper die and the lower die of the die are slightly opened and closed and are in a half-open state, and a surface protection resin material is injected immediately, the function of the surface protection resin material is similar to that of varnish sprayed on a product with a traditional appearance, and the surface protection resin material has the protection function and the attractive effect which are equal to that of the varnish sprayed on the product. The temperature of the mold during injection is still maintained at the curing temperature, then the mold is closed again for curing for 0.5-3 min, and the thickness of the protective layer is 30-400 mu m;
s8: taking a workpiece: and cooling and ejecting after the steps are finished, and taking out the finished exterior trimming part product. The product of the embodiment does not need to be coated subsequently, so that the time and the cost brought by the complicated coating can be further saved.
The steps can select automatic production to realize manual operation to the maximum extent, thereby shortening the production beat, greatly improving the production efficiency and simultaneously improving the production stability and the product quality. The above-mentioned S1-S8 is the production beat of one piece, and the time is less than or equal to 13 min.
Claims (5)
1. A mass production preparation method of a composite material part containing a solar cell film is characterized by comprising the following steps: the component comprises a solar cell film component and a high-performance continuous fiber composite material, and is integrally formed by injecting a fast curing resin by an RTM (resin transfer molding) process, and the method specifically comprises the following steps:
step 1, laying fiber fabrics and cutting the fiber fabrics into material blocks;
step 2, arranging the solar cell thin film assembly on the material block in the step 1;
step 3, placing the material block provided with the solar cell thin film assembly in a mold, closing the mold, vacuumizing, injecting a preheated and mixed resin material, standing under the conditions of heat preservation and mold-keeping pressure after injection, and demolding to obtain a composite material part containing the solar cell thin film;
the material block in the step 1 needs to be preformed, then the solar cell thin film assembly is arranged on the material block, the preforming is to grab the material block to a preheated platform for heating, the temperature reaches the melting temperature of the powder scattering material on the fiber fabric, then the material block is grabbed to a preforming mold and then the mold is closed and cold-pressed for preforming, then the formed preform is grabbed to a preforming tool and the rest edge is cut;
the high-performance continuous fiber composite material is of a laminated plate structure or a sandwich structure, and the thickness is 0.5 mm-20 mm;
the solar cell thin film assembly is a flexible gallium arsenide double-junction or multi-junction cell thin film sheet, and the thickness of the solar cell thin film assembly is less than 20 mu m;
injecting the resin material in the step 3 by adopting a high pressure or medium pressure mode, wherein the high pressure is 30-150 bar, and the medium pressure is 5-30 bar;
in the step 3, the mold temperature is 70-150 ℃, and the resin material is high-performance fast curing epoxy resin.
2. The method of claim 1, wherein: the fiber fabric is made of carbon fiber, glass fiber or mixed fiber, and the fabric is warp-knitted axial fabric or woven fabric.
3. The method of claim 1, wherein: and the standing time in the step 3 is less than 6 min.
4. The method of claim 1, wherein: and 3, after the standing treatment in the step 3 is finished, opening and closing the mold to enable the mold to be in a half-open state, injecting a surface protection resin material, closing the mold and curing, and thus forming a protection layer on the surface of the part.
5. The method of claim 4, wherein: the thickness of the protective layer is 30 mu m-400 mu m.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202010306217.0A CN111452397B (en) | 2020-04-17 | 2020-04-17 | Mass production preparation method of composite material part containing solar cell thin film |
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| Application Number | Priority Date | Filing Date | Title |
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| CN202010306217.0A CN111452397B (en) | 2020-04-17 | 2020-04-17 | Mass production preparation method of composite material part containing solar cell thin film |
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| CN111452397A CN111452397A (en) | 2020-07-28 |
| CN111452397B true CN111452397B (en) | 2021-08-31 |
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Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN105140326A (en) * | 2015-09-21 | 2015-12-09 | 北京昶远科技有限公司 | Structural member having photovoltaic assembly and preparation method thereof |
| EP3006181A2 (en) * | 2014-09-08 | 2016-04-13 | Fundacíon Tecnalia Research & Innovation | Method of encapsulating photovoltaic cells and encapsulated modules |
| CN206856054U (en) * | 2017-05-25 | 2018-01-09 | 辽宁通用航空发展有限公司 | Unmanned plane solar cell board mold laying structure |
-
2020
- 2020-04-17 CN CN202010306217.0A patent/CN111452397B/en active Active
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP3006181A2 (en) * | 2014-09-08 | 2016-04-13 | Fundacíon Tecnalia Research & Innovation | Method of encapsulating photovoltaic cells and encapsulated modules |
| CN105140326A (en) * | 2015-09-21 | 2015-12-09 | 北京昶远科技有限公司 | Structural member having photovoltaic assembly and preparation method thereof |
| CN206856054U (en) * | 2017-05-25 | 2018-01-09 | 辽宁通用航空发展有限公司 | Unmanned plane solar cell board mold laying structure |
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| CN111452397A (en) | 2020-07-28 |
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