TWI614290B - A solar panel frame made of a high solid carbon containing polymer composite particle and a method thereof - Google Patents

Abstract

A solar panel frame made of high-solid carbon content polymer composite particles and a method thereof, wherein a solid carbon material and a solid polymer material are dry-mixed to form an initial mixture; and the initial mixture is subjected to a hot pressing process Obtaining a composite block; applying a first granulation process to the composite block, forming the composite block to form a plurality of first composite particles; and then mixing the first composite particles with an additive, and A second composite particle is formed by a second granulation process, and then the second composite particle is subjected to a forming process to form a solar panel frame having the advantages of good weather resistance and light weight.

Description

Solar panel frame made of polymer composite particles with high solid carbon content and method thereof

The invention relates to a solar panel frame and a manufacturing method thereof, in particular to a solar panel frame made of polymer composite particles with high solid carbon content and a method thereof.

With the continuous advancement of industry, the shortage of exhausted energy such as oil and coal mines, as well as the environmental impact and damage after use, are becoming more and more obvious. It is imperative to improve energy shortages and maintain the environment. For this reason, the use of renewable energy It is also receiving more and more attention; renewable energy, including wind, tidal, geothermal and solar energy from nature, and solar cells are more recently considered because of their unrestricted location and easy source of energy. Future stars in renewable energy.

Solar panels with solar cells are used as substrates, and are commonly used in canopies, hoods, roofs, and building windows, thereby generating power generation, thereby saving a large amount of electricity and effectively achieving energy saving and carbon saving. Effect. For example, US Patent Publication No. US20110155212 discloses a solar panel element comprising a solar panel, a gasket, a metal frame and a thermal paste, the solar panel comprising an upper glass substrate and a lower substrate, the spacer Sealing and clamping the respective edges of the upper glass substrate and the lower substrate, the metal frame covering the spacer, the thermal paste being disposed along the spacer and interconnected between the upper glass substrate and the metal frame or mutual Connected between the lower substrate and the metal frame. Or a solar module bracket for fixing a solar panel, comprising two first fasteners, two second fasteners and a plurality of screws, wherein the first fastener is disposed in the US Patent Publication No. US20110155127 The second fastener is disposed at two opposite sides of the solar panel, and each of the first fasteners and each of the second fasteners respectively comprise a support portion a bottom portion, a connecting portion and a rib portion for supporting the solar panel, the connecting portion for connecting the supporting portion and the bottom portion, the rib portion being disposed between the supporting portion and the bottom portion, A screw is used to lock the first fasteners to the second fasteners, wherein the first fasteners and the second fasteners are made of metal.

It can be seen from the above that most of the solar panel frames are made of metal materials, and in order to effectively increase the power conversion rate of the solar cells, the general solar panels are placed outdoors to absorb sunlight, after a long period of sun and rain. It is easy to have rust and breakage, etc.; and the weight of the metal material is heavy, which often causes inconvenience to the construction personnel.

The main object of the present invention is to solve the conventional frame for a solar panel, which is susceptible to poor weatherability and heavy weight due to the use of metal as a material.

To achieve the above object, the present invention provides a method for manufacturing a solar panel frame using high-solid carbon content polymer composite particles, comprising the following steps:

Forming an initial mixture by dry mixing a solid carbon material and a solid polymer material, the solid carbon material being selected from the group consisting of carbon nanotubes, graphene and carbon black, the solid carbon material being relatively high relative to the solid The weight percentage of the molecular material is greater than or equal to 12%, and the solid polymer material is a powder having a particle diameter of less than 1 mm;

Performing a hot pressing process on the initial mixture to obtain a composite block;

Applying a first granulation process to the composite block, forming the composite block to form a plurality of first composite particles comprising the solid carbon material and the solid polymer material;

Mixing the first composite particles with an additive selected from the group consisting of glass fibers, carbon fibers and nylon 66, and forming a second composite particle by a second granulation process;

The second composite particle is subjected to a forming process to form a solar panel frame.

In order to achieve the above object, the present invention further provides a solar panel frame for fixing a solar panel, the solar panel frame comprising a frame and a support bar, the frame having a first frame strip separated by a first spacing, and two spaced apart a second frame strip disposed between the first frame strips, a connecting structure for connecting adjacent ends between the first frame strips and the second frame strips, and a first connecting structure The frame strip and the second frame strip surround an accommodating space formed for the solar panel, and two ends of the support rod are respectively fixed on the second frame strip and carry the solar panel, wherein the frame and the support The rod system was produced by the aforementioned method.

Accordingly, the present invention has the following features as compared to the prior art:

1. The solid polymer material is used as a substrate to improve the past framework of using a metal material as a solar panel, which has the disadvantages of rust and weather resistance; and the solid state polymer material is added to the solid polymer material according to the present invention. The carbon material enables the formed solar panel frame to have better mechanical strength, so that it can be used to produce the solar panel frame instead of the conventional metal material.

Second, replacing the conventional metal frame with the polymer material as the matrix can reduce the weight of the solar panel frame and facilitate assembly by the construction personnel.

The detailed description and technical content of the present invention will now be described as follows:

Referring to FIG. 1 and FIG. 2A to FIG. 2D, FIG. 1 is a flow chart of steps according to an embodiment of the present invention, and FIG. 2A to FIG. 2D are diagrams of an embodiment of the present invention. Schematic diagram of the manufacturing process, the present invention provides a method for manufacturing a solar panel frame using high-solid carbon content polymer composite particles, comprising the following steps:

Step S1: First, a solid carbon material 10 and a solid polymer material 20 are dry-mixed to form an initial mixture 30, as shown in FIG. 2A. The solid carbon material 10 is a carbon nanotube, graphene, carbon black or a combination thereof. In the present embodiment, the solid carbon material 10 includes a carbon nanotube 10A, a graphene 10B, and a carbon black 10C. The weight percentage of the solid carbon material 10 relative to the solid polymer material 20 is 12% or more, and in other embodiments, the weight percentage of the solid carbon material 10 is preferably between 12% and 95%. The weight percentage of the polymer material 20 is preferably between 5% and 88%, and the weight percentage of the solid carbon material 10 is more preferably between 15% and 70%, and the weight percentage of the solid polymer material 20 More preferably between 30% and 85%. The solid polymer material 20 is a powder having a particle diameter of less than 1 mm, and the solid polymer material 20 is preferably a powder having a particle diameter of less than 500 μm. Further, the solid polymer material 20 is a silicone rubber, a rubber, a thermoplastic polymer material or a combination thereof.

Step S2: forming a composite block 40, applying a forming pressure to the initial mixture 30 at a process temperature to perform a hot pressing process, thereby forming the composite block 40, as shown in FIG. 2B. In the present embodiment, the process temperature is between 50 deg.] C to 410 deg.] C, and the pressure is between 1kgf / cm ² to 960kgf / cm ² between, in another embodiment of the present invention, the molding pressure molding It is preferably between 2 kgf/cm ² and 10 kgf/cm ² . It should be noted that the process temperature and the forming pressure mentioned in the embodiment are only examples, and the invention is not limited thereto, and can be adjusted according to actual use requirements.

Step S3: forming a plurality of first composite particles 50A, that is, performing a first granulation process on the composite block 40, so that the composite block 40 forms the first composite particles 50A, as shown in FIG. 2C. In this embodiment, the first granulation process places the composite block 40 in a pulverizer or a granulator.

Step S4: mixing the first composite particles 50A with an additive 60A, which is glass fiber, carbon fiber, nylon 66 or a combination thereof, and forming a second composite particle 50B by a second granulation process. In this embodiment, the first composite particles 50A may be further mixed with a flame retardant 60B and an anti-ultraviolet agent 60C, as shown in FIG. 2D, but the invention is not limited thereto, and the first composite particles are not limited thereto. 50A and the additive 60A may also be mixed only with the flame retardant 60B or only with the anti-ultraviolet agent 60C. Further, in this step, dry mixing is preferred. In the present invention, the second granulation process may take the same or different equipment or process as the first granulation process.

Step S5: performing a forming process on the second composite particles 50B to form a solar panel frame 70. The forming process may be an injection molding, an extrusion molding, a hot pressing forming, a hydraulic compression forming, and a powder granulation. Forming or a heating step.

The method for manufacturing a solar panel frame using the high solid carbon content polymer composite particles can be used to manufacture the solar panel frame 70 as shown in FIG. 3 and FIG. 4, and the solar panel frame 70 includes a frame 71. With a support rod 72, the frame 71 has two first frame strips 73, two second frame strips 74, and four connecting structures 75. The length of the first frame strips 73 is greater than the second frame strips 74. A frame strip 73 is disposed parallel to each other and separated by a first spacing. The second frame strips 74 are disposed parallel to each other and separated by a second spacing. The connecting structure 75 is connected to one end of the first frame strip 73 and the second frame. Between one end of the strip 74, the first strip 73 and the second strip 74 are surrounded to form an accommodating space 76 for mounting a solar panel 80. Both ends of the support rod 72 are respectively fixed to the second frame strip 74 and carry the solar panel 80. In the embodiment, the first frame strip 73 further includes a first mounting side groove extending from a first outer wall surface of the first frame strip 73, and the second frame strip 74 further includes a second frame. A second mounting side groove extending from the second outer wall surface of the strip 74, the first mounting side groove and the second mounting side groove forming a supporting groove for fixing the solar panel 80.

The connecting structure 75 includes a gusset 751 and a buckle 752. The gusset 751 is disposed at one end of the second frame 74. The buckle 752 is disposed at one end of the first frame 73. The second frame is disposed. The gusset 751 on the 74 is inserted into one end of the first frame strip 73 and is coupled to the buckle 752 of the first frame strip 73. In addition, the second frame strip 74 further has a fixing clip 741 for clamping one end of the support rod 72, that is, the support rod 72 can be fixed. In this embodiment, the support rod 72 is provided. It is an I-shaped member, and the fixing block 741 has a structure complementary to the I-shaped member to be fixedly coupled to each other. By fixing the two ends of the support rod 72 to the second frame strip 74, the structural strength of the solar panel frame 70 can be increased, and the solar panel 80 can be stably supported.

The solar panel frame 70 of the present invention utilizes the solid polymer material 20 as a substrate, and the metal can be used as a substrate as compared with the frame of the conventional solar panel, and the weight can be further reduced. The molecular material 20 is used as a substrate to prevent the frame from being rusted and broken by prolonged exposure to sunlight and rain, thereby improving the life and weather resistance of the solar panel frame 70. Further, since the composite particles include the The solid polymer material 20 further enhances the physical properties of the solar panel frame 70.

In order to verify that the solar panel frame 70 obtained by the method of the present invention has excellent mechanical properties, the applicant further conducted an experimental test on the solar panel frame 70, the data is as follows. The experimental group is the solar panel frame 70 manufactured by the method of the present invention; the control group is the solar panel frame 70 made of an aluminum alloy. In the experimental group, the solid carbon material 10 is a carbon nanotube, graphene and carbon black, and the solid polymer material 20 is a nylon 66 plastic powder, and the solid carbon material 10 is 45 wt.% by weight. The weight percentage of the polymer material 20 was 55 wt.%. The solid carbon material 10 and the solid polymer material 20 are uniformly mixed to obtain the initial mixture 30, and then the hot pressing process is performed at a temperature of 290 ° C and a pressure of 5 kgf / cm ² to obtain the composite block 40. Thereafter, the composite block 40 is pulverized into the first composite particles 50A, and the composite block 40 is formed into the first composite particles 50A including the solid carbon material 10 and the solid polymer material 20, and then the first composite particle 50A is formed. A composite particle 50A and glass fiber, carbon fiber mixed with nylon 66, flame retardant 60B or anti-ultraviolet agent 60C, and the second composite particle 50B is formed by the second granulation process, and then, the second composite particle 50B The forming process is performed, and the forming process is a heating step at a temperature between 250 ° C and 300 ° C to form the solar panel frame 70.

During the stress test, the solar panel frame 70 was first placed on a test platform, and then pressurized, so that the front pressure reached 2400 Pa and the back pressure reached 2400 Pa. The experimental data is as follows. Table 1 Downward pressure test Table 2 Upward stress test

In general, the maximum displacement of glass (Max. glass deformation) needs to be less than 70mm. Exceeding will cause the solar panel power generation efficiency to decrease. The maximum stress of the glass (Max. glass stress) should be less than 80MPa, which will cause the glass to rupture and the frame to be the largest. The stress value (Max. frame stress) needs to be less than 120 MPa, which may cause the frame to break and break. The smaller the above value, the better the representative nature.

In summary, the present invention has the following features:

1. The solid polymer material is used as a substrate to improve the framework of using a metal material as a solar panel in the past, which has the problems of easy rust and poor weather resistance, and it is particularly emphasized that the present invention is superior to the prior art. The solar panel frame has a weather resistance improvement of at least 10 times; at the same time, because the solid carbon material is added to the solid polymer material according to the present invention, the formed solar panel frame can have better mechanical strength, so it can replace the traditional The metal material is used to produce the solar panel frame.

Second, the solid polymer material is used as the matrix to replace the conventional metal frame. Because the density of the solid polymer material is lower than that of the conventional metal frame, the weight of the solar panel frame can be reduced, at least the weight is reduced by 15%, and the construction is convenient. Staff assembly.

The present invention has been described in detail above, but the foregoing is only a preferred embodiment of the present invention, and is not intended to limit the scope of the invention. That is, the equivalent changes and modifications made by the scope of the present application should remain within the scope of the patent of the present invention.

10‧‧‧Solid carbon materials
10A‧‧・nano carbon tube
10B‧‧‧Graphene
10C‧‧‧ carbon black
20‧‧‧Solid polymer materials
30‧‧‧Initial mixture
40‧‧‧Composite blocks
50A‧‧‧First composite particles
50B‧‧‧Second composite particles
60A‧‧‧ Additives
60B‧‧‧Flame retardant
60C‧‧‧Anti-UV agent
70‧‧‧Solar panel frame
71‧‧‧Frame
72‧‧‧Support rod
73‧‧‧ first box
74‧‧‧Second box
741‧‧‧Fixed clamp
75‧‧‧Connection structure
751‧‧‧ gusset
752‧‧‧ buckle seat
76‧‧‧ accommodating space
80‧‧‧ solar panels
S1~S5‧‧‧Steps

FIG. 1 is a flow chart showing the steps of an embodiment of the present invention. 2A to 2D are schematic views showing a manufacturing process according to an embodiment of the present invention. FIG. 3 is a schematic structural view of an embodiment of the present invention. FIG. 4 is an exploded perspective view showing a partial structure of an embodiment of the present invention.

S1~S5‧‧‧Steps

Claims (10)

A method for manufacturing a solar panel frame by using high solid carbon content polymer composite particles, comprising the steps of: dry mixing a solid carbon material and a solid polymer material to form an initial mixture, wherein the solid carbon material is selected from the group consisting of nano a group consisting of carbon tubes, graphenes, and carbon blacks, the solid polymer material being selected from the group consisting of silicone rubber, rubber, and thermoplastic polymer materials, and the weight percentage of the solid carbon material relative to the solid polymer material 12% or more, and the solid polymer material is a powder having a particle diameter of less than 1 mm. In the initial mixture, the weight percentage of the solid carbon material is between 12% and 95%, and the solid polymer material is The weight percentage is between 5% and 88%; the initial mixture is subjected to a hot pressing process to obtain a composite block, and the initial mixture is between 50 ° C and 410 ° C during the hot pressing process. process temperature and a molding interposed between the pressure 1kgf / cm ² to 960kgf / cm ^2; a plurality of packets subjected to a granulation process to the first block of composite material, enabling the formation of lumps of composite material a first composite particle of the solid carbon material and the solid polymer material; mixing the first composite particle with an additive selected from the group consisting of glass fiber, carbon fiber and nylon 66 light agent, and Forming a second composite particle by a second granulation process; and performing a forming process on the second composite particle to form a solar panel frame. The method for manufacturing a solar panel frame according to the high solid carbon content polymer composite particle according to claim 1, wherein the forming process is selected from the group consisting of an injection molding, an extrusion molding, a hot press forming, and a hydraulic compression. A group consisting of forming, a powder granulation, and a heating step. A method for producing a solar panel frame according to the high solid carbon content polymer composite particle according to claim 1, wherein the solid carbon material is between 15% and 70% by weight in the initial mixture. The solid polymer material has a weight percentage of between 30% and 85%. A method for producing a solar panel frame according to the high solid carbon content polymer composite particles according to claim 1, wherein the forming pressure is between 2 kgf/cm ² and 10 kgf/cm ² . The method for producing a solar panel frame according to the high solid carbon content polymer composite particle according to claim 1, wherein the solid polymer material has a particle diameter of less than 500 μm. The method for producing a solar panel frame according to the high solid carbon content polymer composite particles according to claim 1, wherein the first composite particles are further mixed with a flame retardant and an anti-UV agent. A solar panel frame for fixing a solar panel, the solar panel frame comprising: a frame having a first frame strip separated by a first spacing, two spaced apart by a second spacing, and disposed on the first frame a second frame strip between the strips, a connection structure for connecting adjacent ends of the first frame strip and the second frame strip, and a boundary formed by the first frame strip and the second frame strip The accommodating space for the solar panel, the connecting structure comprises a gusset plate and a buckle seat, the gusset plate is disposed on the second frame strip, the buckle seat is disposed on the first frame strip; and a support a rod, which is respectively fixed on the second frame strip and carries the solar panel; wherein the frame and the support rod are made by the method described in claim 1 of the patent application. The solar panel frame of claim 7, wherein the first frame strip further comprises a first mounting side groove extending from a first outer wall surface of the first frame strip, the second frame strip further comprising a second mounting side groove extending from the second outer wall surface of the second frame strip, wherein the first mounting side groove and the second mounting side groove form a supporting groove for fixing the solar panel. The solar panel frame of claim 7, wherein the second frame strip has a fixing clip that clamps one end of the support rod. A solar panel frame is produced by the method described in claim 1 of the patent application.