WO2017215413A1

WO2017215413A1 - Injection molding hyperboloid reflector and injection molding method therefor

Info

Publication number: WO2017215413A1
Application number: PCT/CN2017/085535
Authority: WO
Inventors: 王纪盛; 王国祥; 刘兰兰; 巫育恒
Original assignee: 深圳市昂特尔太阳能投资有限公司
Priority date: 2016-06-15
Filing date: 2017-05-23
Publication date: 2017-12-21
Also published as: JP2017222147A; JP6591359B2; CN106094078A

Abstract

Disclosed are an injection molding hyperboloid reflector and an injection molding method therefor. The injection molding hyperboloid reflector comprises a pedestal (10) which is obtained by employing an injection molding process and which has a hyperboloid concave surface (101), and a reflecting layer (20) connected to the concave surface (101) of the pedestal (10). The pedestal (10) is an integral unit obtained by means of injection molding. The reflecting layer (20) is connected to the concave surface (101) of the pedestal (10) by means of the vacuum coating technology. The pedestal having the hyperboloid concave surface, which is obtained by means of injection molding, has good formability, is easy to install and transport, and facilitates the protection the reflective layer during a transportation process. The pedestal preferably adopts an engineering plastic capable of injection molding, thus has great weatherability and is resistant to deformation, thereby ensuring the service life of the hyperboloid reflector while also being light-weight. Meanwhile, the tolerance between the dimension specification of the hyperboloid concave surface of the hyperboloid reflector and the dimension specification of a theoretically calculated curved surface is small, and the hyperboloid concave surface is almost identical to the designed curved surface, which has excellent light focusing effects, and can improve the light utilization rate. The injection molding process is easily operable.

Description

Injection molding hyperbolic mirror and injection molding method thereof

Technical field

The invention relates to the field of a hyperbolic mirror and a preparation technology thereof, in particular to an injection molding hyperbolic mirror and an injection molding method thereof.

Background technique

In the solar module, the mirror is the main concentrating component, and its concentrating effect directly affects the light conversion efficiency of the solar module.

At present, it has been pointed out that the mirror with a hyperbolic concave surface has a short focal spot and high light efficiency utilization, and is a novel high-efficiency concentrating component. However, due to the high precision of the processing of the concave surface of the hyperboloid, the conventional glass or alloy material is difficult to process, and the processed surface cannot fully conform to the surface equation of the hyperboloid, resulting in a large gap between the hyperbolic concave surface of the actual product and the theory. The result of the concentrating effect is not ideal.

Summary of the invention

In view of the above drawbacks and problems of the prior art, it is an object of the present invention to provide an injection molded hyperboloid mirror and an injection molding method therefor. Solving the technical problem that the conventional glass or alloy material cannot be processed to obtain a highly accurate mirror having a hyperbolic concave surface.

In order to achieve the above object, the present invention provides the following technical solutions:

An injection molded hyperboloid mirror comprising a pedestal having a hyperbolic curved surface obtained by injection molding, and a reflective layer connected to a concave arc surface of the pedestal.

Further, the roughness Ra of the concave curved surface of the susceptor is 0.3 to 0.7 μm.

Further, the base comprises an integrally injection molded panel and branch having a concave curved surface with a hyperboloid Support the base of the panel.

Specifically, the base is a cylinder that is open at both ends, and one end surface cooperates with the contour of the panel.

Further, the thickness of the panel of the susceptor is 2-5 mm. Preferably it is 3 mm. The variation will be adjusted depending on the change in the condensing magnification.

Further, the reflective layer has a thickness of 80 to 200 μm. It is preferably 150 to 180 μm.

Further, the base is made of engineering plastic. Specifically, a composite injection molding material including, but not limited to, one or a combination of at least two of PMMA, PC, PPO, and ABS.

Further, the reflective layer is plated on the concave arc surface of the susceptor by a vacuum coating process.

The vacuum coating process may specifically be vacuum sputtering, vacuum evaporation or vacuum plating. The specific vacuum coating process can be determined according to the material of the specific reflective layer.

Further, the reflective layer is a metal plating layer. Specifically, the metal plating layer is one of a silver plating layer, an aluminum plating layer and a gold plating layer or a composite metal plating layer of at least two kinds of the above, and other plating layers capable of reflecting light can be used as the reflective layer.

Further, the injection molded hyperboloid mirror further includes a mounting lug, and the mounting lug is fixedly coupled to the base. Easy to connect with other components.

Further, the relationship between the concave curved surface of the hyperboloid on the mirror base in the X-axis, the Y-axis, and the Z-axis direction in the three-dimensional coordinate system is as follows: taking a corner of the concave curved surface as an origin, Z=(x ² + y ² ) / 2n, n ranges from 300 mm to 700 mm; where Z is the height in the Z-axis direction, X is the length in the X-axis direction, Y is the length in the Y-axis direction, and the units of X and Y In millimeters. Specifically, the values of X and Y of the hyperbolic mirror are continuous numerical intervals, and the maximum value may be determined according to the size of the actually required hyperbolic mirror, for example, X _max = 400 mm ± 50 mm, Y _max = 380 mm. ±50mm.

An injection molding method for an injection molded hyperboloid mirror of the present invention comprises the following steps:

Step 1. Prepare the susceptor by injection molding: prepare a mold having a cavity conforming to the contour of the mirror base; filling the plastic melt into the cavity of the mold, holding the pressure, cooling, demoulding, and obtaining Pedestal

Step 2: connecting the reflective layer on the concave arc surface of the susceptor prepared in the first step; obtaining an injection molded hyperbolic mirror.

Further, in the first step, the roughness Ra of the convex inner wall of the cavity of the mold matching the concave arc surface of the mirror base is 0.1 to 0.5 μm.

Further, a metal layer is plated on the inner wall of the convex arc surface in the cavity of the mold by a vacuum coating process.

Further, in the first step, the plastic melt at a temperature of 180 to 380 ° C is filled into the cavity of the mold under a filling pressure of 300 to 900 MPa, and then kept under pressure at a temperature of 100 to 150 ° C and a pressure of 400 MPa. 1 to 5 min, then cooled, demolded to obtain a susceptor.

The invention provides an injection molding hyperboloid mirror, which has a concave curved surface with a hyperboloid obtained by an injection molding method, has good formability, is convenient to install, and is convenient to transport, and is more convenient for protecting the reflective layer during transportation.

The base is preferably made of engineering plastic capable of injection molding, has good weather resistance and is not easily deformed, ensures the service life of the hyperbolic mirror, and is light in weight, and has the advantages of small focal length and small footprint of the hyperbolic mirror.

At the same time, the curved surface size specification of the hyperboloid concave curved surface of the hyperbolic mirror of the present invention has a small tolerance of the theoretically calculated curved surface size specification, is almost identical to the designed curved surface, has a good concentrating effect, and improves light utilization efficiency. Parallel light can produce a spot of at least 0.8 mm to 10 mm after passing through the hyperboloid mirror of the present invention. More than a thousand times the concentration effect.

The injection molding method of the injection molding hyperboloid mirror of the invention uses a mold having a cavity conforming to the contour of the mirror base, and injects a plastic solution kept at a certain temperature into the cavity of the mold, and holds the pressure constant. Time, eliminate internal stress, prevent cracking, etc., and finally cool off the mold. The process is simple and easy to operate. The obtained injection molded hyperboloid mirror has small internal stress and does not crack; and the material is uniform.

DRAWINGS

In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the embodiments or the description of the prior art will be briefly described below. Obviously, the drawings in the following description are only It is a certain embodiment of the present invention, and other drawings can be obtained from those skilled in the art without any inventive labor.

Figure 1 is a schematic view showing the structure of an injection molded hyperbolic mirror of the present invention;

2 is a bottom plan view of the injection molded hyperboloid mirror of the present invention.

Detailed ways

The technical solutions of the present invention will be described clearly and completely in conjunction with the embodiments of the present invention. It is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative efforts are within the scope of the present invention.

Example 1

An injection molded hyperboloid mirror of the present invention is illustrated in conjunction with FIGS. 1 and 2, including a susceptor 10 having a hyperbolic concave curved surface 101 injection molded by an injection molding process, and a recess in the pedestal 10. The reflective layer 20 is connected to the curved surface 101.

In order to ensure the smoothness of the reflective layer 20, it is necessary to ensure the roughness of the concave curved surface 101 of the susceptor 10. The degree Ra is 0.3 to 0.7 μm.

The base 10 is made of engineering plastic. It is specifically preferred to use one or a composite injection molding material of at least two of PMMA, PC, PPO, and ABS.

The reflective layer 20 is plated on the concave curved surface 101 of the susceptor 10 by a vacuum coating process. The vacuum coating process may specifically be vacuum sputtering, vacuum evaporation or vacuum plating. The specific vacuum coating process may be determined according to the material of the specific reflective layer 20. The reflective layer 20 is a metal plating layer. Specifically, the metal plating layer is one of a silver plating layer, an aluminum plating layer and a gold plating layer or a composite metal plating layer of at least two kinds of the above, and other plating layers capable of reflecting light can be used as the reflective layer.

In a preferred technical solution of Embodiment 1 of the present invention, the base 10 includes an integrally injection molded panel 11 having a hyperbolic curved surface and a base 12 supporting the panel 11. The base 12 functions as a support panel 11 and its structure is not limited. Specifically, the base 12 can be designed as a cylinder that is open at both ends, and one end surface matches the contour of the panel 11. The base is designed as a hollow structure to further reduce the weight of the hyperbolic mirror. Reduce material usage, reduce costs, and facilitate transportation. The outline of the panel 11 may be rectangular or may be provided in other suitable shapes.

In a further preferred embodiment, the thickness of the panel of the susceptor is 2-5 mm, and the thickness of the reflective layer is 80-200 μm. Preferably, the thickness of the panel of the susceptor is 3 mm, and the thickness of the reflective layer is 150 to 180 μm. The variation will be adjusted depending on the change in the condensing magnification. The wall thickness of the base of the base is not limited as long as it has sufficient support strength.

In order to facilitate the subsequent installation of the hyperboloid mirror, in a preferred embodiment, the injection molding hyperboloid mirror further comprises a mounting lug 13 which is fixedly connected to the base 10. Specifically, as described in FIG. 2, the mounting lug 13 is integrally injection molded with the base 12, and the mounting lug 13 is coupled to one port of the base 12 (the other port opposite to the connecting panel 12). On the edge. In order to adapt to the specific installation conditions, one mounting lug is attached to one edge and the other mounting lug is connected to the other opposite edge.

Example 2

In the second embodiment of the present invention, a relational equation that the curved surface of the hyperboloid concave curved surface 101 of the hyperbolic mirror satisfies is provided. The relationship between the concave curved surface 101 of the hyperboloid on the base 10 of the mirror in the X-axis, Y-axis, and Z-axis directions in the three-dimensional coordinate system is as follows: one corner of the concave curved surface 101 is taken as the origin, Z=( x ² + y ² ) / 2n, n ranges from 300 mm to 700 mm; where Z is the height in the Z-axis direction, X is the length in the X-axis direction, and Y is the length in the Y-axis direction, X and Y The unit is millimeters. The values of X and Y are continuous numerical intervals, X is in the range of (0,400 mm), and Y is in the range of (0,380 mm).

The focal length of the hyperboloid mirror of the second embodiment is between 100 mm and 190 mm; and the focal length of the square Fresnel condenser (380 mm×380 mm) of similar size is in the range of 330 mm to 390 mm, and the hyperbolic reflection of the embodiment can be seen. The focal length of the mirror is significantly reduced, which is about one-half the focal length of a square Fresnel condenser of the same size.

Example 3

The third embodiment of the present invention is a method for preparing an injection molded hyperbolic mirror according to the present invention, comprising the following steps:

In the first step of the third embodiment, in order to ensure that the roughness Ra of the concave curved surface of the susceptor reaches a range of 0.3 to 0.7 μm, it is necessary to form a concave arc surface of the mirror base in the cavity of the mold. cooperative The inner surface of the convex arc surface is specially treated so that the roughness Ra of the inner wall of the convex arc surface is 0.1 to 0.5 μm. Specifically, the roughness of the inner wall of the convex arc surface can be processed to a desired range by applying a metal layer on the inner wall of the convex arc surface by a vacuum plating process.

The injection molding parameters in the injection molding process of the first step of the third embodiment need to be determined according to different plastic types selected.

When using PMMA engineering plastics, the PMMA plastic melt which is kept at a temperature of 200-240 ° C is filled into the cavity of the mold at a filling pressure of 500-600 MPa, and then at a temperature of 140-150 ° C and a pressure of 400 MPa. The insulation is kept for 3 to 5 minutes, then cooled and demolded to obtain a susceptor.

When PC plastic is used, the PC plastic melt which is kept at a temperature of 250-320 ° C is filled into the cavity of the mold under the filling pressure of 800-900 MPa, and then at a temperature of 110-120 ° C and a pressure of 400 MPa. The insulation was kept for 3 to 5 minutes, then cooled and demolded to obtain a susceptor.

When PPO plastic is used, the PPO plastic melt which is kept at a temperature of 260-290 °C is filled into the cavity of the mold at a filling pressure of 700-800 MPa, and then kept at a temperature of 130 ° C and a pressure of 400 MPa. Press for 3 to 5 minutes, then cool and demold to obtain a susceptor.

When ABS plastic is used, the ABS plastic melt which is kept at a temperature of 200-230 ° C is filled into the cavity of the mold under the filling pressure of 300-500 MPa, and then at a temperature of 100-110 ° C and a pressure of 400 MPa. The insulation was kept for 3 to 5 minutes, then cooled and demolded to obtain a susceptor.

The above is only a specific embodiment of the present invention, but the scope of the present invention is not limited thereto, and any person skilled in the art can easily think of changes or substitutions within the technical scope of the present invention. It should be covered by the scope of the present invention. Therefore, the scope of the invention should be determined by the scope of the claims.

Claims

An injection molded hyperboloid mirror comprising a pedestal having a hyperbolic concave curved surface which is injection molded by an injection molding process, and a reflective layer connected on a concave curved surface of the susceptor.
The injection molded hyperbolic mirror according to claim 1, wherein the concave arc surface of the susceptor has a roughness Ra of 0.3 to 0.7 μm.
An injection molded hyperboloid mirror according to claim 1 or 2, wherein the base comprises an integrally injection molded concave curved surface panel and a base supporting the panel.
The injection molded hyperbolic mirror according to claim 3, wherein the thickness of the panel of the susceptor is 2-5 mm; and the thickness of the reflective layer is 80-200 μm.
The injection molded hyperbolic mirror according to claim 1, 2 or 4, wherein the material used by the base includes, but is not limited to, one of PMMA, PC, PPO and ABS or at least two of them Composite injection molding material; the reflective layer is plated on the concave arc surface of the pedestal by a vacuum coating process.
An injection molded hyperboloid mirror according to claim 1, 2 or 4, wherein the injection molded hyperboloid mirror further comprises a mounting lug, the mounting lug being fixedly coupled to the base.
The injection molded hyperboloid mirror according to claim 1, 2 or 4, wherein the concave curved surface of the hyperboloid on the base is in the X-axis, Y-axis and Z-axis directions in the three-dimensional coordinate system The relationship is as follows: the origin of the concave arc surface is taken as the origin, Z=(x 2 +y 2 )/2n, and the value of n ranges from 300 mm to 700 mm; where Z is the height in the Z-axis direction, and X is X. The length in the axial direction, Y is the length in the Y-axis direction, and the units of X and Y are millimeters.
The method of injection molding an injection molded hyperboloid mirror according to any one of claims 1 to 7, comprising the steps of:

Step 1. Prepare the susceptor by injection molding: prepare a mold having a cavity conforming to the contour of the mirror base; filling the plastic melt into the cavity of the mold, holding the pressure, cooling, demoulding, and obtaining Pedestal

Step 2: connecting the reflective layer on the concave arc surface of the susceptor prepared in the first step; obtaining an injection molded hyperbolic mirror.
The injection molding method of an injection molding hyperboloid mirror according to claim 8, wherein in step 1, the inner surface of the convex curved surface of the cavity of the mold is matched with the concave arc surface of the mirror base. The roughness Ra is 0.1 to 0.5 μm; a metal layer is plated on the inner wall of the convex arc surface in the cavity of the mold by a vacuum coating process.
The injection molding method of an injection molded hyperboloid mirror according to claim 8, wherein in step 1, the plastic melt at a temperature of 180 to 380 ° C is filled to the mold under a filling pressure of 300 to 900 MPa. In the cavity, the pressure is maintained at a temperature of 100 to 150 ° C and a pressure of 400 MPa for 1 to 5 minutes, and then cooled and demolded to obtain a susceptor.