Thermoplastic frame based on modified polymethyl methacrylate and manufacturing method thereof

Abstract

The invention relates to a thermoplastic frame based on modified polymethyl methacrylate and a manufacturing method thereof.The thermoplastic frame comprises a clamping part, a supporting part and a fixing part and is integrally formed through pull molding of the same material, and the material comprises thermoplastic polymethyl methacrylate resin, thermoplastic polyolefin, an antioxidant and a stabilizer; the mass ratio of the thermoplastic polymethyl methacrylate resin is greater than 90%. Through material optimization and integrated design, cost is reduced, economical efficiency and sealing performance are improved, defects are reduced, and stable performance is guaranteed. In order to improve the light utilization rate, a reflecting layer is formed on the inner surface of the clamping groove of the laminated piece, light can be reflected, the photoelectric conversion efficiency is improved, the bonding strength is high, and the thermal matching performance is good. The reflecting layer can be a resin prism reflecting structure, the design is optimized, the light utilization rate is improved, and the material cost is reduced. A heat conduction layer can be arranged between the reflecting layer and the clamping part, the upper clamping plate, the lower clamping plate and the longitudinal connecting plate are provided with heat conduction strips or cooling liquid channels, and the cost is reduced and the efficiency is improved through the integrated pull molding technology.

Description

Technical Field

[0001] The present application relates to the technical field of photovoltaic modules, and in particular to a thermoplastic frame based on modified polymethyl methacrylate and a manufacturing method thereof. Background Art

[0002] In the manufacturing and application of photovoltaic modules, the selection of panel frame materials has become a key issue that needs to be solved urgently. Traditionally, photovoltaic module panel frames are mostly made of aluminum alloy, which has the challenges of high carbon emissions, poor corrosion resistance in saline-alkali environments, and high material costs.

[0003] Faced with the limitations of aluminum alloy frames, the industry is actively exploring alternatives. On the one hand, although the attempt to replace aluminum alloy with steel can improve the strength of the frame, the high carbon emissions problem in the steel production process has not been effectively solved, and it is difficult to meet the needs of long-term sustainable development. On the other hand, thermosetting composite materials are regarded as potential substitutes due to their excellent mechanical properties. However, this type of material needs to rely on external coatings to enhance weather resistance when used outdoors for a long time, and it is difficult to recycle and process, which increases the environmental burden and economic cost of the entire life cycle.

[0004] As the cost of photovoltaic power generation continues to decline, the cost of the balance of system (BOS) of photovoltaic power station systems needs to be further compressed to maintain the economic competitiveness of photovoltaic power generation. In particular, as the system voltage moves towards higher standards (such as 1500V), more stringent requirements are placed on the insulation performance, weather resistance and long-term stability of frame materials. In addition, it is worth noting that after the solar cells are laminated, the light emitted from the side is not effectively utilized, which not only causes waste, but also suggests that more functional integration should be considered in the frame design to improve the overall efficiency of photovoltaic modules. In this context, it is necessary to further develop the frame to solve the problems of existing metal frame materials in carbon emissions, corrosion resistance and cost, and explore new paths for photovoltaic module frames to improve photoelectric conversion efficiency, reduce BOS costs and promote material recycling through material innovation and structural optimization. Summary of the invention

[0005] The purpose of the present application is to provide a thermoplastic frame based on modified polymethyl methacrylate and a method for making the same. The frame is realized by a specific material formula and an integrated stretch molding technology, and has lightweight, high heat resistance, halogen-free flame retardancy, good electrical insulation and excellent outdoor performance, so as to meet the multiple demands of the photovoltaic industry for frame materials. The purpose of the present application is achieved through the following technical solutions. The thermoplastic frame based on modified polymethyl methacrylate of the present application includes a clamping portion, a supporting portion and a fixing portion. The clamping portion includes an upper clamping plate, a lower clamping plate and a longitudinal connecting plate. The upper clamping plate, the lower clamping plate and the longitudinal connecting plate form a laminate slot. The supporting portion includes more than two reinforcing connecting plates. The fixing portion includes a horizontal plate connected to the reinforcing connecting plate. The clamping part, the supporting part and the fixing part are integrally drawn and molded from the same material, and the material includes: thermoplastic polymethyl methacrylate resin, thermoplastic polyolefin, antioxidant, and stabilizer; wherein the mass proportion of the thermoplastic polymethyl methacrylate resin is greater than 90%.

[0006] In one embodiment, the material further includes reinforcing fibers, and the extending direction of the reinforcing fibers is the same as the stretch molding direction.

[0007] In one embodiment, the inner surface of the laminate slot includes a reflective layer.

[0008] In one embodiment, the reflective layer is a resin prism reflective structure.

[0009] In one embodiment, a heat conducting layer is included between the reflective layer and the clamping portion.

[0010] In one embodiment, the material further includes silicon oxide-supported silver nanoparticles.

[0011] In addition, the present application further provides a method for manufacturing a thermoplastic frame based on modified polymethyl methacrylate, comprising: mixing raw materials, the raw materials comprising: thermoplastic polymethyl methacrylate resin, thermoplastic polyolefin, antioxidant, stabilizer, wherein the mass proportion of the thermoplastic polymethyl methacrylate resin is greater than 90%; The frame body including a clamping part, a supporting part and a fixing part is formed by integral drawing molding, the clamping part includes an upper clamping plate, a lower clamping plate and a longitudinal connecting plate, the upper clamping plate, the lower clamping plate and the longitudinal connecting plate form a laminate slot, the supporting part includes more than two reinforcing connecting plates, and the fixing part includes a horizontal plate connected to the reinforcing connecting plate.

[0012] In one of the embodiments, the reflective layer is formed on the inner surface by a secondary molding process.

[0013] In one embodiment, a strip mold having a structure complementary to the shape of the prism structure of the reflective layer is used, a resin material forming a resin prism reflective structure is placed at a corresponding position of the strip mold, a laminate slot of the frame body is placed on the strip mold, and heated and pressed into shape.

[0014] In one embodiment, reinforcing fibers are further added to the material, and before the raw materials are mixed, the surfaces of the reinforcing fibers are impregnated with thermoplastic polymethyl methacrylate resin.

[0015] Compared with the prior art, this application has the following beneficial effects: This application uses a high proportion (mass ratio greater than 90%) of thermoplastic polymethyl methacrylate resin as the base material, combined with an integrated stretch molding process, so that the frame can maintain excellent mechanical properties while achieving a significant reduction in overall weight, meeting the technical development needs of lightweight photovoltaic modules. In addition, by adding reinforcing fibers in the same direction as the stretch molding to the material, the strength and modulus of the frame are further improved, and its bearing capacity and deformation resistance are enhanced. The modified polymethyl methacrylate material itself has the characteristics of high heat resistance and long-term heat aging resistance, and is a halogen-free flame retardant material, chlorine-free and bromine-free, meeting environmental protection requirements. The material also exhibits excellent acid and alkali resistance, electrolyte resistance and aging resistance, allowing the frame to operate stably for a long time in harsh environments such as coastal beaches, offshore islands, lakes, ponds, reservoirs, chemical plant roofs, and sewage treatment plants, greatly extending the service life of photovoltaic modules.

[0016] The frame material of the present application has good electrical insulation performance, can effectively prevent current leakage, and ensure the safe operation of photovoltaic power stations. At the same time, it has good dimensional stability, low water absorption (0.06%) and excellent dielectric properties (low Dk value, little affected by temperature, humidity frequency), which ensures the stability and reliability of photovoltaic modules under different environmental conditions. A resin prism reflection structure is set on the inner surface of the laminate slot, and in particular, prism structures of different sizes are used for the upper clamping plate, the lower clamping plate and the longitudinal connecting plate, which effectively improves the reflection utilization rate of the photovoltaic module for the side-emitting light and increases the photoelectric conversion efficiency. In addition, the heat-conducting layer arranged between the reflective layer and the clamping part, as well as the heat-conducting strips or coolant channels contained in the upper clamping plate, the lower clamping plate and the longitudinal connecting plate, further improve the heat dissipation performance of the frame, help to reduce the operating temperature of the photovoltaic module, and improve its power generation efficiency and stability.

[0017] The technical solution of the present application allows different reinforcing materials and resins to be selected according to actual needs to meet different requirements for frame strength, modulus and recyclability. This flexibility not only improves the applicability of the product, but also promotes the recycling of resources, which is in line with the concept of sustainable development. In summary, the thermoplastic frame based on modified polymethyl methacrylate and its production method of the present application have shown obvious technical effect improvements in terms of lightweight, environmental adaptability, electrical insulation performance, light utilization, heat dissipation performance, self-cleaning, material selection and recyclability. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 is a schematic structural diagram of a thermoplastic frame based on modified polymethyl methacrylate in one embodiment of the present application; Figure 2 is a schematic diagram of the cross-sectional structure of a thermoplastic frame based on modified polymethyl methacrylate in one embodiment of the present application; Figure 3 is a schematic diagram of the cross-sectional structure of a thermoplastic frame based on modified polymethyl methacrylate in another embodiment of the present application; Figure 4 It is a schematic flow chart of a method for manufacturing a thermoplastic frame based on modified polymethyl methacrylate in one embodiment of the present application.

[0019] Explanation of reference numerals: 100, clamping portion; 110, upper clamping plate; 120, lower clamping plate; 130, longitudinal connecting plate; 140, laminate slot; 150, reflecting layer; 160, heat conducting layer; 200, supporting portion; 210, reinforcing connecting plate; 300, fixing portion; 310, transverse plate. DETAILED DESCRIPTION

[0020] In order to make the above-mentioned purposes, features and advantages of the present application more obvious and easy to understand, the specific implementation methods of the present application are described in detail below in conjunction with the accompanying drawings. It is to be understood that the specific embodiments described herein are only used to explain the present application, rather than to limit the present application. It should also be noted that, for ease of description, only some structures related to the present application are shown in the accompanying drawings, rather than all structures. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of this application.

[0021] The terms "including" and "having" and any variations thereof in this application are intended to cover non-exclusive inclusions. For example, a process, method, system, product or device comprising a series of steps or units is not limited to the listed steps or units, but may optionally include steps or units not listed, or may optionally include other steps or units inherent to these processes, methods, products or devices.

[0022] Reference to "embodiments" herein means that a particular feature, structure, or characteristic described in conjunction with the embodiments may be included in at least one embodiment of the present application. The appearance of the phrase in various locations in the specification does not necessarily refer to the same embodiment, nor is it an independent or alternative embodiment that is mutually exclusive with other embodiments. It is explicitly and implicitly understood by those skilled in the art that the embodiments described herein may be combined with other embodiments.

[0023] With the continuous growth of the installed capacity of photovoltaic modules, the selection and optimization of its supporting materials have become one of the key factors restricting the further development of the industry. In particular, the frame materials of photovoltaic modules not only need to have sufficient structural strength to support the weight of the module, but also need to achieve new invitations in weather resistance, cost-effectiveness and environmental protection performance to adapt to the increasingly stringent application environment and market demand. The technical solution of this application is a thermoplastic frame based on modified methyl methacrylate (polymethyl methacrylate), which provides a possibility for the upgrading of photovoltaic module frames with an innovative material solution. Modified polymethyl methacrylate materials rely on their unique physical and chemical properties, such as low density, high strength, excellent heat and aging resistance, and halogen-free flame retardant properties. Not only can it effectively reduce the weight of the frame and improve the overall energy efficiency of the module, it can also enhance the durability of the frame in harsh environments and extend the service life of photovoltaic power stations. The following will introduce in detail this thermoplastic frame based on modified polymethyl methacrylate and its production method, and explain the technical characteristics and application advantages from material selection, structural design to production process.

[0024] See also Figures 1 to 3 As shown, a thermoplastic frame based on modified polymethyl methacrylate in a preferred embodiment of the present application includes a clamping portion 100, a supporting portion 200 and a fixing portion 300, wherein the clamping portion 100 includes an upper clamping plate 110, a lower clamping plate 120 and a longitudinal connecting plate 130, wherein the upper clamping plate 110, the lower clamping plate 120 and the longitudinal connecting plate 130 form a laminate slot 140, the supporting portion 200 includes more than two reinforcing connecting plates 210, and the fixing portion 300 includes a transverse plate 310 connected to the reinforcing connecting plate 210, and the clamping portion 100, the supporting portion 200 and the fixing portion 300 are integrally drawn and molded from the same material, and the material includes: thermoplastic polymethyl methacrylate resin, thermoplastic polyolefin, antioxidant, stabilizer; wherein the mass proportion of the thermoplastic polymethyl methacrylate resin is greater than 90%.

[0025] The thermoplastic frame has an integral structure, which is mainly composed of three parts: a clamping part 100, a supporting part 200 and a fixing part 300. The clamping part 100 is composed of an upper clamping plate 110, a lower clamping plate 120 and a longitudinal connecting plate 130, wherein the upper clamping plate 110 and the lower clamping plate 120 are parallel to each other, and the longitudinal connecting plate 130 is vertically connected between the two, and together forms a slot specifically for accommodating laminates. The size and shape of the slot can perfectly match the laminate, ensuring that the laminate is firmly placed in the frame without shaking or displacement. When the integral drawing molding is adopted, the size of the slot can be adjusted very conveniently. The supporting part 200 includes two or more reinforcing connecting plates 210. These reinforcing connecting plates 210 are evenly distributed at specific positions of the frame, which play an important role in enhancing the overall strength and rigidity of the frame, and can effectively disperse the pressure and stress borne by the laminate, and prevent the frame from being deformed or damaged during long-term use. The fixing part 300 is mainly composed of a horizontal plate 310 tightly connected to the reinforcing connecting plate 210. The design of the horizontal plate 310 not only provides additional support for the frame, but also facilitates the installation and fixation of the frame and other components (such as the frame of the photovoltaic module, etc.). Through a reasonable connection method, the horizontal plate 310 can firmly fix the frame in a designated position to ensure the stability of the entire structure.

[0026] In terms of materials, the clamping part 100, the supporting part 200 and the fixing part 300 are all formed by integral drawing of the same carefully formulated material, which is mainly composed of the following components: thermoplastic polymethyl methacrylate resin as the main component, with a mass ratio of more than 90%. Thermoplastic polymethyl methacrylate resin has excellent weather resistance and mechanical properties, and can provide good basic performance for the frame. Thermoplastic polyolefin is used as an auxiliary component, which cooperates with thermoplastic polymethyl methacrylate resin to further improve the processing performance and flexibility of the material, making the frame easier to form, and also improving the impact resistance of the frame. Adding an appropriate amount of antioxidant can effectively prevent the material from aging, discoloration and other problems due to oxidation during long-term use, thereby extending the service life of the frame. UV ultraviolet stabilizer is selected as the main component of the stabilizer. UV ultraviolet stabilizer can absorb or reflect ultraviolet rays to prevent ultraviolet rays from damaging the material, thereby maintaining the appearance and performance of the frame.

[0027] In addition, when the back panel is also made of thermoplastic material, this integrated design concept allows the frame and the back panel to be integrated into one by fusing with the back panel material. This integrated structure not only has a better sealing effect, can effectively prevent moisture, dust and other foreign substances from entering the component, protect the normal operation of the component, but also can further simplify the manufacturing process of the component and reduce production costs.

[0028] The integrated design and material optimization reduce the manufacturing cost of the components and improve the economic efficiency of the components. The reasonable structural design and material selection enable the components to maintain stable performance during long-term use, reducing the power generation loss and maintenance costs caused by component failure. The integrated design allows the frame and the back panel to be designed and manufactured as a whole, improving the integration and sealing of the components, and providing the possibility for subsequent functional expansion (such as integration with the back panel). Through the integrated design and optimization, the material consistency of the clamping part 100, the supporting part 200 and the fixing part 300 is guaranteed, reducing the defects caused by material mismatch or deformation, improving the sealing of the components, effectively preventing the intrusion of external substances such as moisture and dust, protecting the internal structure of the components, and maintaining stable performance in various environments, such as stability under extreme conditions such as high temperature and high humidity, providing a guarantee for subsequent special environment applications.

[0029] Further, the technical solution of the present application can also add reinforcing fibers to the material formula, and the extension direction of these reinforcing fibers is exactly the same as the direction of the drawing and molding. During the material preparation process, the reinforcing fibers are dispersed in the matrix material, and in the integrated drawing and molding process, they can be neatly arranged along the molding direction during the drawing and molding, and this arrangement does not require the use of additional control processes. The reinforcing fibers are arranged along the drawing and molding direction, which can give full play to their high-strength characteristics. When the frame is subjected to tension along the molding direction, the reinforcing fibers can effectively bear most of the tensile stress, thereby greatly improving the tensile strength of the frame. For example, in some application scenarios that need to withstand large tensile forces, such as the frame of photovoltaic modules installed outdoors, this increase in tensile strength can effectively prevent the frame from breaking or deforming due to external force stretching, and ensure the safe and stable operation of the component. When the frame is subjected to bending moment, the reinforcing fibers can provide additional support and reduce the bending deformation of the frame, which is very important for maintaining the shape accuracy and dimensional stability of the frame, especially when the frame needs to support heavier laminates, it can ensure that the position of the laminates is accurate and avoid affecting the photoelectric conversion efficiency of the component due to deformation of the frame.

[0030] In addition, thermoplastic materials usually shrink to a certain extent during the molding process, which may cause inaccurate frame dimensions and affect the fit with laminates and other components. The addition of reinforcing fibers, especially their arrangement in the same direction as the stretch molding, can limit the shrinkage of the material during the molding process. The rigid structure of the reinforcing fibers can resist the shrinkage tendency of the material molecules, making the frame dimensions more stable and reducing installation problems and performance degradation caused by shrinkage. At the same time, during long-term use, the material may undergo creep deformation, that is, over time, the material gradually undergoes slow plastic deformation under constant stress. The presence of reinforcing fibers can effectively inhibit the development of creep deformation. Since the reinforcing fibers have high strength and rigidity, they can withstand part of the stress and slow down the movement of the material molecules, thereby keeping the shape and size of the frame stable for a long time and extending the service life of the frame.

[0031] During the molding process, the material flows along the drawing direction, and the arrangement direction of the reinforcing fibers is consistent with the flow direction, which can reduce the flow resistance inside the material and make it easier for the material to fill the mold cavity, thereby improving the molding quality of the frame. For example, it can reduce the generation of molding defects such as pores and shrinkage marks, make the surface of the frame smoother and flatter, and improve the appearance quality of the product. Since the addition of reinforcing fibers significantly improves the mechanical properties of the frame, the amount of base material used can be reduced while meeting the same performance requirements, which can not only reduce material costs, but also reduce product weight, transportation and installation costs.

[0032] Since resin material is used as the frame, the probability of light reflection at the edge is relatively low. In order to further improve the utilization rate of the side light, a reflective layer 150 with a specific function is formed on the inner surface of the laminate card slot 140. The reflective layer 150 is tightly combined with the substrate by chemical bonding. During the preparation process, the inner surface of the card slot is first pretreated, such as cleaning, activation, etc., to provide a good reaction interface. Then, the resin material with reflective properties is combined with the surface of the card slot substrate to form a strong chemical bond. The use of chemical bonding makes the reflective layer 150 and the card slot substrate have extremely high bonding strength, which can withstand various stresses during the installation and use of the laminate, ensuring that the reflective layer 150 will not fall off or be damaged easily.

[0033] The main function of the reflective layer 150 is to reflect light. The reflective material is fixed on the inner surface of the card slot. In the photovoltaic module finally formed, the reflective layer 150 can reflect the side light into the laminate, thereby increasing the absorption and utilization of light by the battery cells in the laminate, and improving the photoelectric conversion efficiency of the module. The reflective layer 150 can reflect the light that may have been blocked and lost by the card slot back to the laminate, so that more light can be absorbed by the photovoltaic cell and generate more electricity. The chemical bonding connection method makes the bonding strength between the reflective layer 150 and the card slot substrate higher than the physical attachment method. During the installation and use of the laminate, the card slot will be subjected to various external forces, such as thermal stress caused by temperature changes, mechanical vibration, etc. The chemically bonded reflective layer 150 can withstand these stresses without falling off or being damaged, ensuring the long-term stability and reliability of the reflective layer 150. It is precisely because the present application uses polymethyl methacrylate thermoplastic material that this chemical bonding method is achieved. Temperature changes will affect the performance of materials. The physically attached reflective layer 150 may undergo thermal expansion or contraction due to temperature changes, resulting in a decrease in the bonding strength with the card slot substrate. The chemically bonded reflective layer 150 of the present application has better thermal matching due to the formation of chemical bonds with the card slot substrate, and can withstand larger temperature changes without affecting its bonding strength and performance.

[0034] In a specific setting mode, the reflective layer 150 selects a resin prism reflective structure, and can be further optimized according to the propagation path and reflection characteristics of the light in the side of the photovoltaic module. The size of the prism structure set on the upper clamping plate 110 and the lower clamping plate 120 of the photovoltaic module is relatively small. These small-sized prism structures have been accurately calculated and simulated, and their shapes, angles and arrangements have been optimized to adapt to the position and function of the upper and lower clamping plates 120 in the module, and can effectively reflect and scatter the light passing through the area, change the propagation direction of the light, and make the light more effectively reflected inside the module. The size of the prism structure on the longitudinal connecting plate 130 is relatively larger. The longitudinal connecting plate 130 not only plays an important role in connection and support in the frame, but its larger prism structure can more effectively collect and reflect light incident from different angles. Due to the position and angle of the longitudinal connecting plate 130, the large-sized prism structure can capture a wider range of light and reflect these lights back to the laminate at a more favorable angle. From the perspective of light, this combination design of prism structures of different sizes can make light re-enter the laminate faster and more efficiently. By reasonably controlling the size, shape and arrangement of the prisms, the light can be accurately guided and reflected when passing through the reflective layer 150, reducing the scattering and loss of light, and improving the utilization rate of light inside the component. The resin prism reflective structure and the upper clamping plate 110, the lower clamping plate 120 and the longitudinal connecting plate 130 can be integrally formed or firmly connected to ensure the bonding strength between the reflective structure and the component matrix. This high-strength combination can withstand various stresses and vibrations of the component during transportation, installation and use, ensure the stability and reliability of the reflective structure, and extend the service life of the component. Compared with traditional reflective structures such as reflective films, the resin prism reflective structure can be mass-produced by mold molding and other methods, with higher material utilization. Due to the optimized design of the prism structure, the amount of material used can be reduced while ensuring the reflection performance, thereby reducing the material cost of the component.

[0035] In order to further expand the function of the frame, a heat-conducting layer 160 can be provided between the reflective layer 150 and the clamping part 100 described in the present application. The heat-conducting layer 160 is made of a material with high thermal conductivity, such as a metal-based composite material, etc., which can quickly and efficiently conduct the heat generated during the working process from the frame. The upper clamping plate 110, the lower clamping plate 120 and the longitudinal connecting plate 130 can also be provided with a heat-conducting strip or a coolant channel in the structural design. The heat-conducting strip usually adopts a metal material with a high thermal conductivity coefficient, such as copper, aluminum, etc., and through reasonable layout and design, an effective heat conduction path can be formed to quickly transfer heat from the surface of the clamping plate to the external heat dissipation structure. The coolant channel can be designed into different shapes and sizes according to actual needs, and a coolant such as water, ethylene glycol aqueous solution, etc. can be circulated inside. Through the circulation of the coolant, the heat is taken away to achieve efficient heat dissipation. In addition, since the present application adopts an integrated drawing molding technology in the manufacturing process, it melts the plastic material at a high temperature, and then forms a part with a complex shape and structure in a mold through processes such as stretching and blow molding. In the present application, the one-piece stretch molding technology can be used to manufacture the coolant channel at a lower cost and higher efficiency. Compared with traditional machining or welding processes, the one-piece stretch molding technology does not require complicated assembly and connection, reduces the manufacturing process and production cycle, and reduces production costs. At the same time, the one-piece stretch molding can also ensure the sealing and integrity of the coolant channel, avoid failures caused by leakage at the connection, and improve the reliability and stability of the component.

[0036] In order to improve the reflection efficiency and chemical stability at the same time, the present application further introduces silicon oxide loaded silver nanoparticles in the material. Silicon oxide, as a carrier, has the characteristics of high specific surface area, good chemical stability and thermal stability, and provides attachment sites for silver nanoparticles, so that silver nanoparticles can be evenly and stably dispersed on the surface of silicon oxide or in the internal pores. Silver nanoparticles show excellent optical properties by virtue of their unique surface plasma resonance effect. When light is irradiated to the surface of silver nanoparticles, scattering occurs. At the same time, silver nanoparticles also have excellent antibacterial properties. The silver ions released can destroy the cell wall and cell membrane of bacteria, inhibit the growth and reproduction of bacteria, thereby improving the antibacterial and antifouling ability of the material to a certain extent. Applying silicon oxide loaded silver nanoparticles to related products can not only utilize the stability of silicon oxide and the optical and antibacterial properties of silver nanoparticles, but also further optimize the comprehensive performance of the material through the synergistic effect between the two, enhance the absorption and utilization efficiency of light by photovoltaic modules, and improve the photoelectric conversion efficiency.

[0037] See also Figure 4The present application further provides a method for manufacturing a thermoplastic frame based on modified polymethyl methacrylate, comprising: mixing raw materials, the raw materials comprising: thermoplastic polymethyl methacrylate resin, thermoplastic polyolefin, antioxidant, stabilizer, wherein the mass proportion of the thermoplastic polymethyl methacrylate resin is greater than 90%, and integrally drawing and molding to form a frame body comprising a clamping portion 100, a supporting portion 200 and a fixing portion 300, the clamping portion 100 comprising an upper clamping plate 110, a lower clamping plate 120 and a longitudinal connecting plate 130, the upper clamping plate 110, the lower clamping plate 120 and the longitudinal connecting plate 130 forming a laminate slot 140, the supporting portion 200 comprising more than two reinforcing connecting plates 210, and the fixing portion 300 comprising a transverse plate 310 connected to the reinforcing connecting plate 210.

[0038] The manufacturing method of the thermoplastic frame of the present application specifically includes: precise mixing of raw materials, and precise mixing of multiple raw materials according to a preset formula, wherein the raw materials include: thermoplastic polymethyl methacrylate resin, thermoplastic polyolefin, antioxidant, stabilizer and other components. Among them, the mass ratio of thermoplastic polymethyl methacrylate resin is strictly controlled within a range greater than 90%, and various raw materials are fully mixed and uniformly through mixing equipment, such as a twin-screw extruder, etc., to ensure the performance consistency of each part. An integrated drawing molding process is adopted to process and mold the uniformly mixed raw materials in one time to form a frame body with a complex structure. Thermoplastic polymethyl methacrylate resin is used as the main component, and its mass ratio is greater than 90%, so that the frame has the characteristics of high strength and high hardness. Polymethyl methacrylate resin itself has good impact resistance and toughness, and can withstand large external forces without being easily deformed or broken. The addition of thermoplastic polyolefin further enhances the flexibility and processability of the material, so that the frame can absorb energy through its own deformation when impacted by external forces, reducing the risk of damage. For example, during the installation and use of photovoltaic modules, the frame may be subjected to external forces such as wind loads and snow loads. The frame made of this modified polymethyl methacrylate material can better protect the photovoltaic modules and extend their service life. It should be noted that the modification here is not limited to the addition of other components, but can also further include adding other types of substituents to the polymethyl methacrylate material. The one-piece stretch molding process can achieve one-time molding of complex structures, avoiding the errors caused by multiple assemblies and connections in traditional processing techniques. The laminate slot 140 formed by the upper clamping plate 110, the lower clamping plate 120 and the longitudinal connecting plate 130 has high dimensional accuracy and can fit closely with the laminate to ensure the installation accuracy and stability of the laminate. The position and shape of the reinforcing connecting plate 210 and the cross plate 310 can also be precisely controlled to ensure the stability and reliability of the overall structure of the frame. The one-piece stretch molding process has efficient production capacity and can complete the manufacture of the frame in a shorter time, reducing material waste and labor costs in the production process, and reducing production costs. The frame body formed by one-piece stretch molding has good sealing performance. Good sealing performance can prevent moisture penetration from causing short circuits and corrosion of photovoltaic cells, and improve the reliability and service life of photovoltaic modules. The thermoplastic frame based on modified polymethyl methacrylate has good adaptability and versatility, and can be widely used in photovoltaic laminate products of different types and specifications. Both polymethyl methacrylate resin and thermoplastic polyolefin are recyclable materials. The frames made of this material can be recycled and reprocessed after the end of the product life cycle, reducing pollution to the environment. At the same time, the one-piece stretch molding process does not require the use of a large amount of chemical solvents and adhesives, reducing the risk of environmental pollution during the production process.

[0039] In order to further improve the optical performance and functional characteristics of the product, a secondary molding manufacturing method is used to accurately form a uniform and highly reflective reflective layer 150 on the inner surface of the frame laminate slot 140. After the frame main structure is obtained by the first molding, according to the requirements of the secondary molding process, a special material with excellent optical reflective performance is selected, such as a composite material of high-purity aluminum powder and a specific resin, and the reflective material is evenly applied to the inner surface of the frame by embossing. During the embossing process, the process parameters such as temperature, pressure, spraying speed, etc. are controlled to ensure that the reflective material can be fully filled to form a flat and smooth reflective layer 150. Subsequently, after a specific curing treatment, the reflective material is closely combined with the inner surface of the frame to form a stable and durable reflective structure.

[0040] In order to accurately and efficiently construct the resin prism reflection structure, a strip mold with a structure that is precisely complementary to the shape of the target prism structure of the reflection layer 150 is used, and the shape of the mold perfectly matches the prism structure to be formed subsequently. In the process operation, the special resin material for forming the resin prism reflection structure is first placed on the corresponding position of the strip mold according to the preset amount and position. The resin material has good fluidity and optical properties after a special formula (existing technology), and can form a uniform and regular prism structure during the molding process. Then, the laminate slot 140 of the frame body is sleeved on the strip mold. The design of the laminate slot 140 matches the overall structure of the frame body, and its size and shape are precisely measured and processed to ensure a close fit with the strip mold. During the insertion process, it is necessary to ensure that the position between the laminate slot 140 and the strip mold is accurate to avoid deviations that affect the subsequent molding quality. Then, heating and pressing are performed. During the heating process, the heating temperature and heating time are controlled according to the characteristics of the resin material and the shape of the required prism structure, so that the resin material gradually softens after being heated and fills the gaps in the strip mold. At the same time, appropriate pressure is applied to promote the resin material to form a regular prism structure in the mold. After pressing and molding, the resin material is cooled and solidified to obtain a frame with a resin prism reflection structure.

[0041] Before the raw material mixing process, the reinforcing fiber needs to be professionally surface pretreated, that is, the surface of the reinforcing fiber is fully impregnated with thermoplastic methyl methacrylate (PMMA) resin using a specific process. During the impregnation process, the reinforcing fiber must first be strictly cleaned to remove impurities, oil stains and oxide layers on the fiber surface to ensure that the fiber surface has good wettability and activity. This can be achieved through chemical cleaning, plasma treatment and other methods to improve the bonding strength between the fiber and the thermoplastic PMMA resin. The treated reinforcing fiber is immersed in a pre-prepared thermoplastic PMMA resin solution. The concentration, temperature and impregnation time of the solution are precisely controlled according to the type and specification of the reinforcing fiber. Through auxiliary means such as stirring and vacuuming, the thermoplastic PMMA resin is fully penetrated into the microstructure of the reinforcing fiber to form a uniform resin coating. After the impregnation is completed, the impregnated reinforcing fiber is properly dried to remove excess solvent so that the resin forms a stable solidified layer on the fiber surface. After being impregnated with thermoplastic polymethyl methacrylate resin, the interfacial bonding strength between the reinforcing fibers and the resin matrix is ​​improved, effectively avoiding the debonding and slippage between the fibers and the resin. The mechanical properties of the composite material, such as tensile strength, flexural strength and impact strength, can be improved, and the stress concentration and microcrack propagation of the composite material under cyclic load can be reduced, thereby improving its fatigue resistance and reducing the risk of failure due to fatigue damage. Specific embodiments

[0043] Some specific implementation methods will be further introduced below to further explain the technical solution of this application in detail.

[0044] In the first embodiment, the raw materials include: 90% thermoplastic polymethyl methacrylate resin, 8% thermoplastic polyolefin, 1% antioxidant, 1% stabilizer, and the thickness is selected to be 1.3 mm.

[0045] In the second embodiment, the raw materials include: 95% thermoplastic polymethyl methacrylate resin, 3% thermoplastic polyolefin, 1% antioxidant, 1% stabilizer, and the thickness is 2 mm.

[0046] In the third embodiment, the raw materials include: 97% thermoplastic polymethyl methacrylate resin, 2% thermoplastic polyolefin, 0.5% antioxidant, 0.5% stabilizer, and the thickness is 2 mm.

[0047] Comparative Example 1 It uses a conventional aluminum alloy frame with a thickness of 1.3mm.

[0048] Tests and results, the embodiments and comparative examples were tested, including appearance, assembly dimension deviation, weight, CASS salt spray test, wear resistance, sealing test, wet leakage current test, insulation test, mechanical load test, chemical resistance, TUV / UL low temperature impact, HAST96, high temperature baking, DH1000, wet cold test, TC200, and the test results are shown in Table 1.

[0049] Table 1 Test results of various embodiments and comparative examples

[0050] The polymethyl methacrylate frame has a design life of up to 30 years, ensuring long-term and stable operation of the components; it has excellent resistance to acid, alkali and salt spray corrosion, can adapt to complex and harsh environments, and reduce maintenance costs. In highly corrosive scenarios such as coastal mudflats, offshore islands, and chemical plant roofs, the polymethyl methacrylate frame exhibits significant advantages due to its acid, alkali, electrolyte, and aging resistance.

[0051] The tensile strength is 100MPa, and it can be designed to be thicker than aluminum alloy. The density is only 1.08g / cm³ (aluminum alloy is 2.7g / cm³), and the frame weight is reduced by 42% (for example, a polymethyl methacrylate frame with 1.5 times the volume of an aluminum frame weighs only 1.1kg), meeting the lightweight requirements of photovoltaic modules. The thermal expansion coefficient is 6×10 -5 / ℃, better than aluminum alloy (3×10 -5 / ℃), ensuring long-term use without deformation and improving component reliability. The breakdown voltage DS reaches 44kV / mm, with excellent electrical insulation performance; the dielectric constant Dk=2.5, the loss factor Df=0.0007, is less affected by temperature, humidity, and frequency, ensuring signal transmission stability.

[0052] Polymethyl methacrylate is a self-flame retardant material. After modification, it is easy to achieve halogen-free flame retardancy, meet environmental protection requirements, and reduce fire risks. It has obvious cost advantages: the cost of aluminum frames is 38 yuan / piece, while polymethyl methacrylate frames are only 27 yuan / piece, reducing costs by 29%, improving the economic benefits of the project. The modified polymethyl methacrylate material has low density and light weight, taking into account both performance and cost, and meeting the development needs of lightweight technology. In outdoor scenes such as lakes, ponds, reservoirs, and sewage treatment plants, the aging resistance and corrosion resistance of polymethyl methacrylate frames significantly extend the life of components. Different reinforcement materials and resins can be selected according to strength, modulus, and recyclability requirements to flexibly adapt to a variety of application scenarios.

[0053] As can be seen from the foregoing, the present application provides a thermoplastic frame based on modified polymethyl methacrylate and a method for making the same, wherein the frame is integrally formed by drawing of a clamping portion, a supporting portion and a fixing portion, and adopts a material system with a thermoplastic polymethyl methacrylate resin having a mass fraction greater than 90% as the core, combined with thermoplastic polyolefins, antioxidants and UV stabilizers, and material performance optimization is achieved through precise proportioning. The clamping portion forms a laminate slot through the upper / lower clamping plates and the longitudinal connecting plates, the supporting portion includes multiple sets of reinforced connecting plates, and the fixing portion achieves structural reinforcement and installation adaptation through the transverse plates. This design improves the weather resistance, mechanical strength and dimensional stability of the frame through material modification and structural coordination, while reducing manufacturing costs.

[0054] In terms of material innovation, this application can further enhance the tensile strength by directional arrangement of reinforced fibers (consistent with the direction of drawing). Its rigid structure can inhibit material shrinkage and creep deformation, reduce molding defects and optimize weight distribution. In addition, chemical bonding technology is used to combine the reflective layer with the card slot matrix, and the resin prism reflective structure (small-sized prisms on the upper / lower clamping plates and large-sized prisms on the longitudinal connecting plates) is used to achieve efficient use of side light. The coordinated design of the reflective layer and the thermal conductive layer further enhances the photoelectric conversion efficiency and heat dissipation performance of the component. The introduction of silicon oxide-loaded silver nanoparticles improves the optical and chemical stability of the material through the dual effects of surface plasma resonance effect and antibacterial properties.

[0055] In terms of manufacturing process, this application adopts integrated drawing and molding technology to achieve high-precision manufacturing of complex structures, and ensures the integration of the frame body and the functional layer through steps such as raw material mixing, molding processing, secondary reflective layer and prism structure construction. Among them, the reflective layer forms a high-reflectivity coating through an embossing process and curing treatment, and the prism structure adopts a strip mold and heated pressing molding technology to ensure precise control of optical performance. The pretreatment process of the reinforced fiber achieves a strong interface bonding between the fiber and the resin matrix through steps such as surface cleaning, impregnation and drying, thereby improving the mechanical properties and fatigue resistance of the composite material.

[0056] The above is only a specific implementation of the present application, and any other improvements made based on the concept of the present application are deemed to be within the protection scope of the present application.

Claims

1. A thermoplastic frame based on modified polymethyl methacrylate, characterized in that: It comprises a clamping part, a supporting part and a fixing part, wherein the clamping part comprises an upper clamping plate, a lower clamping plate and a longitudinal connecting plate, wherein the upper clamping plate, the lower clamping plate and the longitudinal connecting plate form a laminate slot, the supporting part comprises more than two reinforcing connecting plates, and the fixing part comprises a transverse plate connected to the reinforcing connecting plate; The clamping part, the supporting part and the fixing part are integrally drawn and molded from the same material, and the material includes: thermoplastic polymethyl methacrylate resin, thermoplastic polyolefin, antioxidant, and stabilizer; wherein the mass proportion of the thermoplastic polymethyl methacrylate resin is greater than 90%.

2. The thermoplastic frame based on modified polymethyl methacrylate according to claim 1, characterized in that: The material also includes reinforcing fibers, and the extending direction of the reinforcing fibers is the same as the direction of stretch molding.

3. The thermoplastic frame based on modified polymethyl methacrylate according to claim 1, characterized in that: The inner surface of the laminate slot includes a reflective layer.

4. The thermoplastic frame based on modified polymethyl methacrylate according to claim 3, characterized in that: The reflective layer is a resin prism reflective structure.

5. The thermoplastic frame based on modified polymethyl methacrylate according to claim 3, characterized in that: A heat conducting layer is included between the reflective layer and the clamping portion.

6. The thermoplastic frame based on modified polymethyl methacrylate according to claim 1, characterized in that: The material also includes silicon oxide-supported silver nanoparticles.

7. A method for manufacturing a thermoplastic frame based on modified polymethyl methacrylate, characterized in that: include: Mixing raw materials, the raw materials include: thermoplastic polymethyl methacrylate resin, thermoplastic polyolefin, antioxidant, stabilizer, wherein the mass proportion of the thermoplastic polymethyl methacrylate resin is greater than 90%; The frame body including a clamping part, a supporting part and a fixing part is formed by integral drawing molding, the clamping part includes an upper clamping plate, a lower clamping plate and a longitudinal connecting plate, the upper clamping plate, the lower clamping plate and the longitudinal connecting plate form a laminate slot, the supporting part includes more than two reinforcing connecting plates, and the fixing part includes a horizontal plate connected to the reinforcing connecting plate.

8. The method for manufacturing a thermoplastic frame based on modified polymethyl methacrylate according to claim 7, characterized in that: A reflective layer is formed on the inner surface by a secondary molding method.

9. The method for manufacturing a thermoplastic frame based on modified polymethyl methacrylate according to claim 8, characterized in that: A strip mold having a structure complementary to the shape of the prism structure of the reflective layer is used, and the resin material forming the resin prism reflective structure is placed at the corresponding position of the strip mold, and the laminate slot of the frame body is sleeved on the strip mold, and heated and pressed to form.

10. The method for manufacturing a thermoplastic frame based on modified polymethyl methacrylate according to claim 7, characterized in that: Reinforcement fibers are further added to the material, and before the raw materials are mixed, the surfaces of the reinforcement fibers are impregnated with thermoplastic polymethyl methacrylate resin.

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