Weather-resistant photovoltaic pipe and forming method thereof

Abstract

The forming method comprises the following steps: providing a polypropylene base material and an additive, and carrying out pre-drying treatment on the polypropylene base material and the additive according to a preset weight percentage; melting and mixing the pretreated polypropylene base material and an additive in a range of 190-220 DEG C by using a twin-screw extruder, carrying out extrusion molding by using a circular mold, rapidly cooling the extruded thermoplastic pipe to room temperature by using a continuous water cooling device, and sizing by using a sizing roller way; the cooled pipe is moderately stretched in the longitudinal direction and the transverse direction through a two-way stretching device, and online detection is conducted through detection equipment; through collaborative optimization of the materials and the process, the produced weather-resistant photovoltaic pipe has excellent ultraviolet resistance, oxidation resistance and mechanical properties and is suitable for a photovoltaic system environment with high requirements, and high-quality preparation of the weather-resistant photovoltaic pipe is achieved.

Description

Technical Field

[0001] The present invention relates to the technical field of photovoltaic pipes, and in particular to a weather-resistant photovoltaic pipe and a forming method thereof. Background Art

[0002] With the transformation of the global energy structure and the widespread application of renewable energy, photovoltaic power generation has developed rapidly as a clean and efficient form of energy. Photovoltaic systems are widely used in residential, commercial buildings, agricultural facilities, and power supply in remote areas. In these applications, photovoltaic brackets are an important component for fixing and supporting photovoltaic components, and their performance directly affects the stability and service life of photovoltaic systems. Therefore, the development of photovoltaic bracket materials with high strength, weather resistance and excellent mechanical properties is of great significance to improving the overall performance and reliability of photovoltaic systems.

[0003] In the prior art, photovoltaic brackets are mostly made of metal materials such as aluminum alloy or steel. Although these materials have certain mechanical strength and durability, they still have many shortcomings in practical applications. First, metal materials are prone to oxidation and aging in environments with high ultraviolet radiation and extreme temperature changes, resulting in a decrease in material performance and shortened service life. Secondly, the processing and molding process of metal materials is complicated and costly, and stress concentration is prone to occur during the production process, affecting the overall stability of the bracket. In addition, traditional metal photovoltaic brackets are insufficient in terms of impact resistance and creep resistance, and it is difficult to meet the high environmental requirements of photovoltaic systems.

[0004] Therefore, there is an urgent need for a new type of weather-resistant photovoltaic tube and its forming method, which can overcome the shortcomings of the existing technology through the coordinated optimization of materials and processes and achieve high-quality weather-resistant photovoltaic tube production to meet the needs of modern photovoltaic systems for high-performance components. Summary of the invention

[0005] The purpose of the present invention is to provide a weather-resistant photovoltaic tube and a forming method thereof to solve the above technical problems.

[0006] To achieve this object, the present invention adopts the following technical solutions: A method for forming a weather-resistant photovoltaic tube, comprising: Providing a polypropylene substrate and an additive, and pre-drying the polypropylene substrate and the additive according to a preset weight percentage; the additive includes long glass fiber, a UV stabilizer, an antioxidant, a heat stabilizer, an impact agent and a processing aid; Using a twin-screw extruder, the pretreated polypropylene substrate and the additive are melt-mixed at a temperature of 190-220° C., and extruded through a circular die to form a preliminary thermoplastic pipe; A continuous water cooling device is used to quickly cool the extruded thermoplastic pipe to room temperature, and the diameter tolerance of the pipe is controlled within a preset range through a sizing roller. The cooled tube is passed through a biaxial stretching device to be appropriately stretched in the longitudinal and transverse directions to obtain a formed photovoltaic tube; The appearance, size and mechanical properties of the formed photovoltaic tubes are tested online through testing equipment, and the qualified photovoltaic tubes are cut, bundled and packaged according to the preset length.

[0007] Optionally, the ultraviolet stabilizer comprises a nano titanium dioxide ultraviolet absorber and a polymer-based light stabilizer prepared by nanocomposite technology, and the total content thereof is 0.5-1.5 weight percent; The antioxidant comprises an organic antioxidant and an inorganic antioxidant synthesized by enzyme catalysis, and the total content thereof is 0.5-1.0 weight percent.

[0008] Optionally, the long glass fiber is selected from any one or more of E glass fiber, S glass fiber, C glass fiber and AZS glass fiber, and its content is 20-30 weight percent; The heat stabilizer is selected from any one or more of a hydroxyl radical inhibitor, a flame retardant and a thermoplastic enhancer, and its content is 0.3-0.5 weight percent; The anti-impact agent is selected from any one or more of butadiene rubber, ethylene-vinyl acetate copolymer and styrene-butadiene rubber, and its content is 0.2-0.5 weight percent; The processing aid is selected from any one or more of a lubricant, a dispersant and a rheology modifier, and its content is 0.1-0.5 weight percent.

[0009] Optionally, the pretreated polypropylene substrate and the additive are melt-mixed at a temperature of 190-220° C. using a twin-screw extruder, and extruded through a circular die to form a preliminary thermoplastic pipe, specifically comprising: Introducing the pretreated polypropylene substrate and the additive into the feed port of the twin-screw extruder through a screw conveying system; A multi-zone temperature control system is set in the twin-screw extruder, wherein the multi-zone temperature control system includes a heating zone and a cooling zone, wherein the temperature gradient of the heating zone is controlled between 190-220°C, and the temperatures of the heating zone and the cooling zone are monitored in real time by an infrared temperature sensor; A variable cross-section screw design is used in the heating zone to extrude the thermoplastic material; In the cooling zone, a multi-channel cooling component is used to evenly cool the circular die to control the cross-sectional roundness and dimensional stability of the tube during the extrusion process; After extrusion molding is completed, the initially formed thermoplastic pipe is guided to the next process.

[0010] Optionally, the thermoplastic material further comprises an optimization step during the extrusion process: Introducing a highly efficient dispersant during the extrusion process to promote uniform distribution of long glass fibers in the polypropylene matrix through dynamic dispersion technology; During the extrusion molding process, a real-time online monitoring system is set up, which includes a pressure sensor and a flow meter to dynamically monitor and adjust the pressure and flow during the extrusion process; The operating parameters of the twin-screw extruder are optimized and adjusted through the temperature detection data of the infrared temperature sensor, and the operating parameters include screw speed, pressure and temperature.

[0011] Optionally, the method of using a continuous water cooling device to quickly cool the extruded thermoplastic pipe to room temperature and controlling the diameter tolerance of the pipe within a preset range through a sizing roller conveyor specifically includes: The extruded thermoplastic pipe is guided to a continuous water cooling device through a pre-cooling conduit, wherein the pre-cooling conduit adopts a double-layer structure design, and the double-layer structure includes a water-permeable inner layer and a ventilation outer layer; In the continuous water cooling device, a multi-stage water spray system is used to carry out the rough cooling stage and the fine cooling stage in sequence, including: Rough cooling stage: Use a high-pressure water nozzle to evenly spray 5-10 liters of water per second on the surface of the thermoplastic pipe to quickly reduce the surface temperature of the pipe to 80-100°C; Fine cooling stage: Use low-pressure water mist spraying to perform fine cooling at a water flow rate of 1-3 liters per second to further reduce the temperature of the thermoplastic pipe to room temperature; The temperature of the cooling water is maintained constant through a constant temperature circulating water system, specifically controlling the cooling water temperature between 15-25°C, and a heat exchanger is used to pre-cool the circulating water; A cooling water recovery device is set at the outlet of the continuous water cooling device to recover the waste water generated during the cooling process, and the waste water is recycled through a filtration and treatment system.

[0012] Optionally, a cooling water recovery device is provided at the outlet of the continuous water cooling device to recover waste water generated during the cooling process, and the waste water is recycled through a filtering and treatment system, and then the method further includes: The thermoplastic pipe cooled to room temperature is conveyed to a sizing roller, wherein the sizing roller is designed with an adjustable roller spacing, and the roller spacing is adjusted in real time according to the detected diameter data; A stabilizing device is installed at the exit of the sizing roller table to stabilize the shape and size of the pipe through buffer rollers and tension control system.

[0013] Optionally, the cooled tube is stretched appropriately in the longitudinal direction and the transverse direction respectively by a biaxial stretching device to obtain a formed photovoltaic tube, which specifically includes: The cooled thermoplastic pipe is conveyed to a biaxial stretching device, wherein the biaxial stretching device comprises a longitudinal stretching module and a transverse stretching module; In the longitudinal stretching module, a servo motor-driven stretching system is used to control the longitudinal stretching ratio of the pipe between 2:1 and 4:1, so that the pipe can obtain uniform stress distribution and dimensional stability in the longitudinal direction; In the transverse stretching module, a pneumatic or hydraulically driven stretching system is used to control the transverse stretching ratio of the pipe between 1.5:1 and 3:1.

[0014] Optionally, in the transverse stretching module, a pneumatic or hydraulically driven stretching system is used to control the transverse stretching ratio of the tube to be between 1.5:1 and 3:1, and then further comprising: Introduce a temperature control system to heat or cool the pipe accordingly during the stretching process, and control the temperature of the pipe to be kept between 40-60°C during the stretching process; Set up multi-point stress monitoring sensors to monitor the stress changes of the pipe in the longitudinal and transverse stretching process in real time, and dynamically adjust the stretching parameters through the control system; After stretching is completed, the residual stress in the tube is gradually released through the buffer roller and tension control system to obtain a formed photovoltaic tube.

[0015] The present invention also provides a weather-resistant photovoltaic tube, which adopts the above-mentioned method for forming the weather-resistant photovoltaic tube, and the components of the weather-resistant photovoltaic tube specifically include: A main substrate, a main substrate of the tube body composed of a polypropylene substrate; A reinforcing phase, a long glass fiber reinforcing phase uniformly dispersed in the polypropylene matrix; and an ultraviolet stabilizer, an antioxidant, a heat stabilizer, an impact-resistant agent and a processing aid dispersed in the polypropylene matrix.

[0016] Compared with the prior art, the present invention has the following beneficial effects: firstly, a polypropylene substrate and additives including long glass fibers, ultraviolet stabilizers, antioxidants, heat stabilizers, impact inhibitors and processing aids are provided, and pre-dried according to a preset weight percentage to remove moisture; then, the pre-treated polypropylene substrate and the additives are melt-mixed by a twin-screw extruder at a temperature range of 190-220° C., extruded through a circular die to form a preliminary thermoplastic pipe, a continuous water cooling device is used to quickly cool the extruded thermoplastic pipe to room temperature, and a diameter tolerance of the pipe is controlled within 0.040° C. by a sizing roller. Within the preset range, ensure accurate size and stable shape; then pass the cooled pipe through a biaxial stretching device, and stretch it moderately in the longitudinal and transverse directions to improve the mechanical strength and dimensional stability of the pipe, and finally obtain a formed photovoltaic pipe. The appearance, size and mechanical properties of the formed photovoltaic pipe are tested online by testing equipment. After passing the test, the pipe is cut, bundled and packaged according to the preset length to complete the entire forming process; through the coordinated optimization of materials and processes, the weather-resistant photovoltaic pipe produced by this method has excellent UV resistance, oxidation resistance and mechanical properties, is suitable for high-demand photovoltaic system environments, and achieves high-quality preparation of weather-resistant photovoltaic pipes. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative labor.

[0018] The structures, proportions, sizes, etc. illustrated in the drawings of this specification are only used to match the contents disclosed in the specification so as to facilitate understanding and reading by persons familiar with this technology. They are not used to limit the conditions under which the present invention can be implemented, and therefore have no substantive technical significance. Any structural modification, change in proportion or adjustment of size, without affecting the effects and purposes that can be achieved by the present invention, should still fall within the scope of the technical contents disclosed by the present invention.

[0019] Figure 1 This is one of the flow diagrams of the method for forming a weather-resistant photovoltaic tube according to the first embodiment of the present invention; Figure 2 This is the second schematic flow diagram of the method for forming the weather-resistant photovoltaic tube of the first embodiment. DETAILED DESCRIPTION

[0020] In order to make the purpose, features and advantages of the present invention more obvious and easy to understand, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the embodiments described below are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0021] In the description of the present invention, it should be understood that the terms "upper", "lower", "top", "bottom", "inside", "outside" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation of the present invention. It should be noted that when a component is considered to be "connected" to another component, it may be directly connected to the other component or there may be a centrally arranged component at the same time.

[0022] The technical solution of the present invention is further described below with reference to the accompanying drawings and through specific implementation methods.

[0023] Embodiment 1: Combination Figure 1 to Figure 2 As shown, an embodiment of the present invention provides a method for forming a weather-resistant photovoltaic tube, comprising: S1, providing a polypropylene substrate and an additive, and pre-drying the polypropylene substrate and the additive according to a preset weight percentage; the additive includes long glass fiber, a UV stabilizer, an antioxidant, a heat stabilizer, an impact agent and a processing aid; First, a polypropylene substrate and a variety of functional additives are provided, and they are pre-dried according to a preset weight percentage. The pre-drying treatment effectively removes the moisture in the polypropylene substrate, preventing bubbles or material degradation caused by water evaporation during the subsequent melt mixing process, thereby ensuring the purity and consistency of the material. The selected additives, including long glass fibers, UV stabilizers, antioxidants, heat stabilizers, impact agents and processing aids, not only enhance the mechanical strength and weather resistance of the pipe, but also optimize the processing performance of the material. This step controls and optimizes the ratio to ensure that the final photovoltaic pipe has excellent UV resistance, antioxidant and mechanical properties, meeting the high-demand environmental requirements of photovoltaic systems.

[0024] S2, using a twin-screw extruder to melt-mix the pretreated polypropylene substrate and the additive in the range of 190-220° C., and extruding through a circular die to form a preliminary thermoplastic pipe; The pretreated polypropylene substrate and additives are melt-mixed in the range of 190-220°C using a twin-screw extruder, and extruded through a circular die to form a preliminary thermoplastic pipe. In this process, the design of the twin-screw extruder ensures the full mixing and uniform dispersion of the polypropylene substrate and various additives, avoiding uneven material during extrusion. The use of a circular die ensures the roundness of the pipe cross section and the accuracy of the size, improving the overall quality and consistency of the pipe. This step ensures that the initially formed thermoplastic pipe has good mechanical properties and processing stability by optimizing the melt mixing and extrusion molding process.

[0025] S3, using a continuous water cooling device to quickly cool the extruded thermoplastic pipe to room temperature, and controlling the diameter tolerance of the pipe within a preset range through a sizing roller; The extruded thermoplastic pipe is quickly cooled to room temperature by a continuous water cooling device, and the diameter tolerance of the pipe is controlled within a preset range by a sizing roller. The rapid cooling process uses an advanced water cooling system to achieve rapid cooling of the pipe, preventing material deformation and stress concentration caused by uneven temperature gradients. In addition, the intelligent control system of the sizing roller is equipped with a high-precision diameter sensor and a servo motor drive device, which can monitor and adjust the roller spacing in real time to ensure that the pipe diameter tolerance remains within ±0.5%.

[0026] S4, passing the cooled tube through a biaxial stretching device, and appropriately stretching it in the longitudinal direction and the transverse direction respectively, to obtain a formed photovoltaic tube; The cooled pipe is moderately stretched longitudinally and transversely by a biaxial stretching device to obtain a formed photovoltaic pipe. The biaxial stretching process uses a stretching system driven by a high-precision servo motor to stretch uniformly in the longitudinal and transverse directions, respectively, to ensure that the pipe obtains balanced stress distribution and dimensional stability in both directions. The temperature control system is introduced to properly heat or cool the pipe during the stretching process, maintain the pipe within a temperature range of 40-60°C, optimize the tensile performance, and prevent stress concentration and uneven deformation caused by temperature fluctuations. In addition, the application of multi-point stress monitoring sensors and bidirectional synchronous feedback control mechanisms realizes real-time monitoring and dynamic adjustment of the stretching process, ensuring balanced stress distribution of the pipe during the biaxial stretching process to avoid excessive or under-stretching. This step significantly improves the mechanical strength and dimensional stability of the pipe through precise stretching control, making it have excellent UV resistance, antioxidant and mechanical properties, and is suitable for high-demand photovoltaic system environments.

[0027] S5, the appearance, size and mechanical properties of the formed photovoltaic tubes are tested online by testing equipment, and the qualified photovoltaic tubes are cut, bundled and packaged according to the preset length.

[0028] During inspection, a high-vision inspection system is used to identify and remove surface defects such as bubbles, cracks and spots in real time to ensure the quality of product appearance; a laser diameter gauge and mechanical property testing device are used to accurately measure the diameter and mechanical properties of the pipe to ensure that it meets the design requirements. Automatic cutting equipment and bundling equipment ensure the consistency and neat arrangement of the pipes according to the preset length to prevent deformation or damage during storage and transportation. The use of moisture-proof and UV-proof packaging materials further protects the pipes from environmental factors during storage and transportation, extending their service life. The introduction of a full-process automated control system and data management system has achieved efficient management and quality control of the production process, ensuring that the final product has excellent appearance, size and mechanical properties.

[0029] The working principle of the present invention is as follows: firstly, a polypropylene substrate and additives including long glass fibers, ultraviolet stabilizers, antioxidants, heat stabilizers, impact resistant agents and processing aids are provided, and pre-dried according to a preset weight percentage to remove moisture; then, a twin-screw extruder is used to melt-mix the pre-treated polypropylene substrate and the additives within a temperature range of 190-220° C., and the pre-treated polypropylene substrate and the additives are extruded through a circular die to form a preliminary thermoplastic pipe; a continuous water cooling device is used to quickly cool the extruded thermoplastic pipe to room temperature, and a sizing roller is used to control the diameter tolerance of the pipe within a preset range. , ensuring accurate size and stable shape; then the cooled pipe is passed through a biaxial stretching device and moderately stretched in the longitudinal and transverse directions to improve the mechanical strength and dimensional stability of the pipe, and finally a formed photovoltaic pipe is obtained. The formed photovoltaic pipe is subjected to online inspection of appearance, size and mechanical properties by means of testing equipment. After passing the inspection, the pipe is cut, bundled and packaged according to the preset length to complete the entire forming process; through the coordinated optimization of materials and processes, the weather-resistant photovoltaic pipe produced by this method has excellent UV resistance, oxidation resistance and mechanical properties, is suitable for high-demand photovoltaic system environments, and realizes high-quality preparation of weather-resistant photovoltaic pipes.

[0030] In this embodiment, as a preferred solution, the ultraviolet stabilizer includes a nano titanium dioxide ultraviolet absorber prepared by nanocomposite technology and a polymer-based light stabilizer, and the total content thereof is 0.5-1.5 weight percent.

[0031] The antioxidant comprises an organic antioxidant and an inorganic antioxidant synthesized by enzyme catalysis, and the total content of the antioxidant is 0.5-1.0 weight percent.

[0032] Among them, the UV stabilizer is compounded with nano-titanium dioxide and polymer-based light stabilizer through nano-composite technology to form a composite stabilizer with high-efficiency UV absorption and scattering capabilities, which significantly improves the UV resistance of the pipe; the antioxidant is synthesized through enzyme catalysis, and has higher antioxidant activity and better dispersibility, which effectively prevents the performance degradation of the pipe caused by oxidation during long-term use.

[0033] In this embodiment, it is specifically stated that the component of the long glass fiber is selected from any one or more of E glass fiber, S glass fiber, C glass fiber and AZS glass fiber, and its content is 20-30 weight percent; the heat stabilizer is selected from any one or more of hydroxyl radical inhibitors, flame retardants and thermoplastic enhancers, and its content is 0.3-0.5 weight percent; the impact agent is selected from any one or more of butadiene rubber, ethylene-vinyl acetate copolymer and styrene-butadiene rubber, and its content is 0.2-0.5 weight percent; the processing aid is selected from any one or more of lubricants, dispersants and rheology modifiers, and its content is 0.1-0.5 weight percent.

[0034] In this embodiment, it is specifically described that step S2 specifically includes: S21, introducing the pretreated polypropylene substrate and additives into the feed port of the twin-screw extruder through a screw conveying system; the twin-screw extruder adopts a uniform mixing screw configuration to ensure sufficient mixing of the polypropylene substrate and the additives.

[0035] The pretreated polypropylene substrate and additives are introduced into the feed port of the twin-screw extruder through the screw conveying system. The screw conveying system ensures that the polypropylene substrate and additives enter the extruder evenly and continuously, thereby ensuring a stable supply of materials before entering the melt mixing zone. This process effectively prevents interruptions or uneven input of materials during the extrusion process, ensures the smooth subsequent melt mixing, and improves the quality and consistency of the formed pipe.

[0036] S22, setting a multi-zone temperature control system in the twin-screw extruder, the multi-zone temperature control system including a heating zone and a cooling zone, wherein the temperature gradient of the heating zone is controlled between 190-220° C., and the temperatures of the heating zone and the cooling zone are monitored in real time by an infrared temperature sensor; The application of the multi-zone temperature control system ensures precise temperature control in different zones, maintains the temperature uniformity of the material during the melt mixing process, prevents material degradation or unstable performance due to temperature fluctuations, and thus improves the efficiency of melt mixing and the overall quality of the pipe.

[0037] S23, a variable cross-section screw design is used in the heating zone to extrude thermoplastic materials; the variable cross-section screw design is used to optimize the compression ratio and pitch of the screw to improve the shear uniformity and mixing efficiency of the material and reduce the decomposition and degradation of the material during the extrusion process.

[0038] S24, in the cooling zone, a multi-channel cooling member is used to uniformly cool the circular die to control the cross-sectional roundness and dimensional stability of the tube during the extrusion molding process; In the cooling zone, a multi-channel cooling component is used to evenly cool the circular die to control the cross-sectional roundness and dimensional stability of the tube during the extrusion process. The multi-channel cooling component ensures uniform temperature distribution of the die through multi-point and uniform cooling, so that the cross-sectional roundness and dimensional accuracy of the extruded tube are maintained, avoiding tube deformation and stress concentration caused by uneven temperature gradients, and improving the geometric accuracy and surface finish of the tube.

[0039] S25, after the extrusion molding is completed, the initially formed thermoplastic pipe is guided to the next process to reduce the residence time of the material under high temperature state and prevent performance degradation and deformation.

[0040] In this embodiment, it is specifically stated that the thermoplastic material further includes an optimization step during the extrusion process: S231, introduces a high-efficiency dispersant during the extrusion process to promote the uniform distribution of long glass fibers in the polypropylene matrix through dynamic dispersion technology; Introducing high-efficiency dispersants during the extrusion process promotes the uniform distribution of long glass fibers in the polypropylene matrix through dynamic dispersion technology. The use of high-efficiency dispersants effectively prevents the agglomeration of long glass fibers, ensures their uniform dispersion in the matrix, significantly improves the mechanical strength and weather resistance of the pipe, optimizes the processing performance of the material, and enhances the reliability and service life of the pipe in practical applications.

[0041] S232, during the extrusion molding process, a real-time online monitoring system is set up, the online monitoring system includes a pressure sensor and a flow meter, and the pressure and flow rate during the extrusion process are dynamically monitored and adjusted; During the extrusion process, a real-time online monitoring system is set up. The online monitoring system includes a pressure sensor and a flow meter to dynamically monitor and adjust the pressure and flow during the extrusion process. The application of the real-time online monitoring system can timely detect and adjust abnormal conditions during the extrusion process, maintain the stability and consistency of the extrusion process, ensure that the quality and performance of the pipe meet the expected standards, and improve the controllability and automation level of the production process.

[0042] S233, optimizing and adjusting the operating parameters of the twin-screw extruder through the temperature detection data of the infrared temperature sensor, the operating parameters including the screw speed, pressure and temperature.

[0043] The temperature detection data from the infrared temperature sensor is used to optimize and adjust the operating parameters of the twin-screw extruder, including screw speed, pressure and temperature. The real-time feedback of the temperature detection data enables the extruder to dynamically adjust the screw speed, pressure and temperature according to the actual temperature state of the material, optimize the melt mixing and extrusion process, and improve production efficiency and product quality. At the same time, the application of the intelligent control system realizes efficient energy utilization and energy-saving production in the extrusion process, ensuring the thermodynamic stability and performance consistency of the pipe throughout the molding process.

[0044] In this embodiment, it is specifically described that step S3 specifically includes: S31, guiding the extruded thermoplastic pipe to a continuous water cooling device through a pre-cooling conduit, the pre-cooling conduit adopts a double-layer structure design, the double-layer structure includes a water-permeable inner layer and a ventilation outer layer; so as to accelerate the initial cooling process of the pipe and reduce deformation caused by uneven temperature gradient.

[0045] The extruded thermoplastic pipe is guided to the continuous water cooling device through the pre-cooling duct. The pre-cooling duct adopts a double-layer structure design, which includes a water-permeable inner layer and a ventilated outer layer. The double-layer design of the pre-cooling duct effectively realizes the initial cooling of the pipe. The heat of the pipe is quickly taken away by the water passing through the inner layer, while the outer layer ventilation accelerates the cooling process, ensuring that the temperature of the pipe has been greatly reduced before entering the main cooling stage. This design not only improves the cooling efficiency and shortens the cooling time, but also reduces the deformation and stress concentration of the pipe caused by uneven temperature gradient, ensuring the quality and stability of the pipe during the subsequent cooling and sizing process.

[0046] S32, in the continuous water cooling device, a multi-stage water spray system is used to sequentially perform the rough cooling stage and the fine cooling stage, specifically including: Rough cooling stage: Use a high-pressure water nozzle to evenly spray 5-10 liters of water per second on the surface of the thermoplastic pipe to quickly reduce the surface temperature of the pipe to 80-100°C; the high-pressure water nozzle can effectively take away the heat on the surface of the pipe in a short time, significantly shorten the cooling time, and avoid the thermal stress and deformation problems caused by rapid cooling of the pipe.

[0047] Fine cooling stage: low-pressure water mist spraying is used to perform fine cooling at a water flow rate of 1-3 liters per second to further reduce the temperature of the thermoplastic pipe to room temperature; low-pressure water mist spraying can achieve more uniform and gentle cooling, ensure the overall temperature balance of the pipe, and prevent stress concentration and material performance degradation caused by excessive temperature difference between the inside and outside.

[0048] S33, maintaining the temperature of cooling water constant through a constant temperature circulating water system, specifically controlling the cooling water temperature between 15-25°C, and using a heat exchanger to pre-cool the circulating water; to improve cooling efficiency and water resource utilization.

[0049] The application of the constant temperature circulating water system ensures that the cooling water maintains a constant temperature throughout the cooling process, avoiding uneven cooling caused by water temperature fluctuations. At the same time, the introduction of the heat exchanger can effectively reduce the temperature of the circulating water, improve cooling efficiency, and reduce energy consumption. In addition, through pre-cooling treatment, the temperature of the circulating water can be controlled within the optimal range, further improving the overall performance and environmental protection of the cooling system, and realizing an efficient and energy-saving cooling process.

[0050] S34, a cooling water recovery device is provided at the outlet of the continuous water cooling device to recover waste water generated during the cooling process, and the waste water is recycled through a filtering and treatment system.

[0051] S35, transports the thermoplastic pipe cooled to room temperature to the sizing roller. The sizing roller adopts a roller design with adjustable roller spacing. The roller spacing is adjusted in real time through the detected diameter data. This sizing system not only improves the dimensional accuracy and consistency of the pipe, but also can promptly respond to diameter deviations that may occur during the production process, reduce the defective rate, and improve production efficiency and product quality stability.

[0052] S36, a stabilizing device is installed at the exit of the sizing roller table to stabilize the shape and size of the pipe through the buffer roller and tension control system. This prevents elastic rebound and deformation during the sizing process and ensures the geometric accuracy and surface finish of the pipe.

[0053] In this embodiment, it is specifically explained that step S4 specifically includes: S41, conveying the cooled thermoplastic pipe to a biaxial stretching device, which includes a longitudinal stretching module and a transverse stretching module.

[0054] S42, in the longitudinal stretching module, a servo motor-driven stretching system is used to control the longitudinal stretching ratio of the pipe between 2:1 and 4:1, so that the pipe can obtain uniform stress distribution and dimensional stability in the longitudinal direction.

[0055] S43, in the transverse stretching module, a pneumatic or hydraulically driven stretching system is used to control the transverse stretching ratio of the pipe between 1.5:1 and 3:1; by precisely adjusting the stretching speed and strength, uniform deformation of the pipe in the transverse direction is achieved.

[0056] S44, introduces a temperature control system to perform corresponding heating or cooling treatment on the pipe during the stretching process, and controls the temperature of the pipe to be maintained between 40-60°C during the stretching process; in order to optimize the stretching performance and prevent stress concentration and uneven deformation of the pipe caused by temperature fluctuations.

[0057] S45, set up multi-point stress monitoring sensors to monitor the stress changes of the pipe in the longitudinal and transverse stretching process in real time, and dynamically adjust the stretching parameters through the control system.

[0058] S46, after the stretching is completed, the residual stress in the tube is gradually released through the buffer roller and the tension control system to obtain a formed photovoltaic tube. This prevents the tube from being deformed or broken during subsequent use, and ensures the dimensional stability and mechanical strength of the formed photovoltaic tube.

[0059] Embodiment 2: The present invention further provides a weather-resistant photovoltaic tube, which adopts the forming method of the weather-resistant photovoltaic tube in the first embodiment. The weather-resistant photovoltaic tube specifically comprises: The main substrate is a tube body main substrate composed of a polypropylene substrate.

[0060] The reinforcing phase is a long glass fiber reinforcing phase uniformly dispersed in a polypropylene matrix; the long glass fiber is selected from E glass fiber, S glass fiber, C glass fiber and AZS glass fiber.

[0061] A UV stabilizer dispersed in a polypropylene matrix; the UV stabilizer comprises a composite of nano titanium dioxide (TiO2) and a polymer-based light stabilizer prepared by nanocomposite technology.

[0062] Antioxidants, antioxidants dispersed in a polypropylene matrix, antioxidants including organic antioxidants synthesized by enzyme catalysis and high-efficiency inorganic antioxidants.

[0063] A heat stabilizer is dispersed in a polypropylene matrix, wherein the heat stabilizer is selected from a hydroxyl radical inhibitor, a flame retardant and a thermoplastic enhancer.

[0064] The impact-resistant agent is dispersed in the polypropylene matrix, and the impact-resistant agent is selected from butadiene rubber, ethylene-vinyl acetate copolymer (EVA) and styrene-butadiene rubber (SBR).

[0065] A processing aid, a processing aid dispersed in a polypropylene matrix, wherein the processing aid is selected from a lubricant, a dispersant and a rheology modifier.

[0066] As described above, the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit the same. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that the technical solutions described in the aforementioned embodiments may still be modified, or some of the technical features thereof may be replaced by equivalents. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for forming a weather-resistant photovoltaic tube, characterized in that: include: Providing a polypropylene substrate and an additive, and pre-drying the polypropylene substrate and the additive according to a preset weight percentage; the additive includes long glass fiber, a UV stabilizer, an antioxidant, a heat stabilizer, an impact agent and a processing aid; Using a twin-screw extruder, the pretreated polypropylene substrate and the additive are melt-mixed at a temperature of 190-220° C., and extruded through a circular die to form a preliminary thermoplastic pipe; A continuous water cooling device is used to quickly cool the extruded thermoplastic pipe to room temperature, and the diameter tolerance of the pipe is controlled within a preset range through a sizing roller. The cooled tube is passed through a biaxial stretching device to be appropriately stretched in the longitudinal and transverse directions to obtain a formed photovoltaic tube; The appearance, size and mechanical properties of the formed photovoltaic tubes are tested online through testing equipment, and the qualified photovoltaic tubes are cut, bundled and packaged according to the preset length.

2. The method for forming a weather-resistant photovoltaic tube according to claim 1, characterized in that: The ultraviolet stabilizer comprises a nano titanium dioxide ultraviolet absorber and a polymer-based light stabilizer prepared by nanocomposite technology, and the total content thereof is 0.5-1.5 weight percent; The antioxidant comprises an organic antioxidant and an inorganic antioxidant synthesized by enzyme catalysis, and the total content thereof is 0.5-1.0 weight percent.

3. The method for forming a weather-resistant photovoltaic tube according to claim 2, characterized in that: The component of the long glass fiber is selected from any one or more of E glass fiber, S glass fiber, C glass fiber and AZS glass fiber, and its content is 20-30 weight percent; The heat stabilizer is selected from any one or more of a hydroxyl radical inhibitor, a flame retardant and a thermoplastic enhancer, and its content is 0.3-0.5 weight percent; The anti-impact agent is selected from any one or more of butadiene rubber, ethylene-vinyl acetate copolymer and styrene-butadiene rubber, and its content is 0.2-0.5 weight percent; The processing aid is selected from any one or more of a lubricant, a dispersant and a rheology modifier, and its content is 0.1-0.5 weight percent.

4. The method for forming a weather-resistant photovoltaic tube according to claim 1, characterized in that: The method of using a twin-screw extruder to melt-mix the pretreated polypropylene substrate and the additive at a temperature of 190-220° C. and extruding the mixture through a circular die to form a preliminary thermoplastic pipe comprises: Introducing the pretreated polypropylene substrate and the additive into the feed port of the twin-screw extruder through a screw conveying system; A multi-zone temperature control system is set in the twin-screw extruder, wherein the multi-zone temperature control system includes a heating zone and a cooling zone, wherein the temperature gradient of the heating zone is controlled between 190-220°C, and the temperatures of the heating zone and the cooling zone are monitored in real time by an infrared temperature sensor; A variable cross-section screw design is used in the heating zone to extrude the thermoplastic material; In the cooling zone, a multi-channel cooling component is used to evenly cool the circular die to control the cross-sectional roundness and dimensional stability of the tube during the extrusion process; After extrusion molding is completed, the initially formed thermoplastic pipe is guided to the next process.

5. The method for forming a weather-resistant photovoltaic tube according to claim 4, characterized in that: The thermoplastic material also includes optimization steps during the extrusion process: Introducing a highly efficient dispersant during the extrusion process to promote uniform distribution of long glass fibers in the polypropylene matrix through dynamic dispersion technology; During the extrusion molding process, a real-time online monitoring system is set up, which includes a pressure sensor and a flow meter to dynamically monitor and adjust the pressure and flow during the extrusion process; The operating parameters of the twin-screw extruder are optimized and adjusted through the temperature detection data of the infrared temperature sensor, and the operating parameters include screw speed, pressure and temperature.

6. The method for forming a weather-resistant photovoltaic tube according to claim 1, characterized in that: The method of using a continuous water cooling device to quickly cool the extruded thermoplastic pipe to room temperature and controlling the diameter tolerance of the pipe within a preset range through a sizing roller conveyor specifically includes: The extruded thermoplastic pipe is guided to a continuous water cooling device through a pre-cooling conduit, wherein the pre-cooling conduit adopts a double-layer structure design, and the double-layer structure includes a water-permeable inner layer and a ventilation outer layer; In the continuous water cooling device, a multi-stage water spray system is used to carry out the rough cooling stage and the fine cooling stage in sequence, including: Rough cooling stage: Use a high-pressure water nozzle to evenly spray 5-10 liters of water per second on the surface of the thermoplastic pipe to quickly reduce the surface temperature of the pipe to 80-100°C; Fine cooling stage: Use low-pressure water mist spraying to perform fine cooling at a water flow rate of 1-3 liters per second to further reduce the temperature of the thermoplastic pipe to room temperature; The temperature of the cooling water is maintained constant through a constant temperature circulating water system, specifically controlling the cooling water temperature between 15-25°C, and a heat exchanger is used to pre-cool the circulating water; A cooling water recovery device is set at the outlet of the continuous water cooling device to recover the waste water generated during the cooling process, and the waste water is recycled through a filtration and treatment system.

7. The method for forming a weather-resistant photovoltaic tube according to claim 6, characterized in that: The cooling water recovery device is arranged at the outlet of the continuous water cooling device to recover the waste water generated during the cooling process, and the waste water is recycled through the filtering and treatment system, and then further includes: The thermoplastic pipe cooled to room temperature is conveyed to a sizing roller, wherein the sizing roller is designed with an adjustable roller spacing, and the roller spacing is adjusted in real time according to the detected diameter data; A stabilizing device is installed at the exit of the sizing roller table to stabilize the shape and size of the pipe through buffer rollers and tension control system.

8. The method for forming a weather-resistant photovoltaic tube according to claim 1, characterized in that: The cooled tube is passed through a biaxial stretching device to be appropriately stretched in the longitudinal direction and the transverse direction to obtain a formed photovoltaic tube, which specifically includes: The cooled thermoplastic pipe is conveyed to a biaxial stretching device, wherein the biaxial stretching device comprises a longitudinal stretching module and a transverse stretching module; In the longitudinal stretching module, a servo motor-driven stretching system is used to control the longitudinal stretching ratio of the pipe between 2:1 and 4:1, so that the pipe can obtain uniform stress distribution and dimensional stability in the longitudinal direction; In the transverse stretching module, a pneumatic or hydraulically driven stretching system is used to control the transverse stretching ratio of the pipe between 1.5:1 and 3:

1.

9. The method for forming a weather-resistant photovoltaic tube according to claim 8, characterized in that: In the transverse stretching module, a pneumatic or hydraulically driven stretching system is used to control the transverse stretching ratio of the pipe to be between 1.5:1 and 3:1, and then further comprising: Introduce a temperature control system to heat or cool the pipe accordingly during the stretching process, and control the temperature of the pipe to be kept between 40-60°C during the stretching process; Set up multi-point stress monitoring sensors to monitor the stress changes of the pipe in the longitudinal and transverse stretching process in real time, and dynamically adjust the stretching parameters through the control system; After stretching is completed, the residual stress in the tube is gradually released through the buffer roller and tension control system to obtain a formed photovoltaic tube.

10. A weather-resistant photovoltaic tube, characterized in that: The method for forming a weather-resistant photovoltaic tube according to any one of claims 1 to 9 is adopted, wherein the components of the weather-resistant photovoltaic tube specifically include: A main substrate, a main substrate of the tube body composed of a polypropylene substrate; A reinforcing phase, a long glass fiber reinforcing phase uniformly dispersed in the polypropylene matrix; and an ultraviolet stabilizer, an antioxidant, a heat stabilizer, an impact-resistant agent and a processing aid dispersed in the polypropylene matrix.

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