A mold for making a luminescent solar concentrator

Abstract

The utility model discloses a kind of molds for making light-emitting solar concentrator, including mold main body, the glass forming closed forming chamber is embedded in both sides of the mold main body, the pouring port is provided at the top of the mold main body, LSC slurry is poured into closed forming chamber by pouring port;Several clamps are provided on the side wall of the mold main body, and the clamp is used to clamp the glass of both sides of mold main body.This mold supports single production line multi-mold synchronous operation, the stable clamping of glass by clamp, cooperate closed forming chamber, can ensure the forming condition of each set of mold uniform, reduce quality fluctuation from root source.This mold has high-precision forming surface, can ensure that the LSC surface made reaches enough flatness, reduces the light scattering, refraction loss caused by surface unevenness, improves the capture and transmission efficiency of LSC to light.

Description

Technical Field

[0001] This utility model relates to the field of building-integrated photovoltaics technology, specifically to a mold for manufacturing luminescent solar concentrators. Background Technology

[0002] With the increasing demand for high-efficiency, low-cost photovoltaic technology in the global new energy industry, light-emitting solar concentrators (LSCs), as a new type of component that can concentrate large-area sunlight into photovoltaic cells, have become an important research direction in the photovoltaic field due to their advantages such as lightweight, flexible adaptation, and low photovoltaic cell usage. After years of technological iteration, the core material performance of LSCs has gradually matured, and key indicators such as transmittance and concentration efficiency in the laboratory stage have reached the standards for commercial application.

[0003] At this stage, mass production technology has become the core bottleneck restricting LSC from the laboratory to the market. Unlike small-batch preparation in the laboratory, commercial applications demand LSC products with characteristics of "large scale, high consistency, and low cost": on the one hand, downstream applications need to purchase thousands or even tens of thousands of LSC products at a time, requiring the production process to have stable mass production capabilities; on the other hand, as the core concentrating component of photovoltaic systems, the dimensional accuracy and light transmission performance of LSCs directly affect the overall power generation efficiency of photovoltaic systems. Poor product consistency will lead to difficulties in module adaptation and inconsistent power generation efficiency, failing to meet the reliability requirements of commercial applications. The special structure and molding characteristics of LSCs determine that their mass production must rely on dedicated molds. However, there is currently no dedicated mold design solution for LSC mass production in the publicly available technology field. In existing small-batch LSC production, most use temporary molding devices of "self-made simple frame + transparent film covering". Given the maturity of LSC technology, the urgent need for commercialization, and the lack of dedicated mass production molds, it is necessary to develop a dedicated mold that adapts to the molding characteristics of LSCs, ensures product quality consistency, and is compatible with mass production efficiency.

[0004] Therefore, this utility model provides a mold for manufacturing a light-emitting solar concentrator. Utility Model Content

[0005] The purpose of this invention is to provide a mold for manufacturing light-emitting solar concentrators, so as to overcome the shortcomings of existing technologies such as poor product consistency and low mass production efficiency.

[0006] To achieve the above objectives, the present invention provides the following technical solution: This utility model discloses a mold for manufacturing a light-emitting solar concentrator, comprising a mold body, with glass embedded on both sides of the mold body to form a closed molding chamber, and an injection port provided on the top of the mold body, through which LSC slurry is injected into the closed molding chamber; and several clamps are provided on the side wall of the mold body, the clamps being used to clamp the glass on both sides of the mold body.

[0007] Furthermore, a sealing gasket is provided between the mold body and the glass.

[0008] Furthermore, the thickness of the sealing gasket is 0.1~0.3mm.

[0009] Furthermore, the fixture includes a fixture body and a chuck, the chuck being connected to the fixture body via a pivot.

[0010] Furthermore, the top of the mold body is provided with an exhaust hole.

[0011] Furthermore, the injection port is sealed with a cap.

[0012] Furthermore, the main body of the mold is made of polytetrafluoroethylene.

[0013] Furthermore, mounting grooves are provided on the edges of the sides of the mold body, and the sealing gasket and glass are sequentially embedded in the mounting grooves.

[0014] Furthermore, the clamp is provided with an elastic buffer pad.

[0015] Furthermore, the clamp body is provided with an adjustment knob, which is connected to the rotating shaft for transmission. By rotating the adjustment knob, the clamping force of the clamp on the glass can be controlled.

[0016] Compared with the prior art, the present invention has the following beneficial technical effects: This invention provides a mold for manufacturing light-emitting solar concentrators. The standardized components, consisting of the mold body, glass, inlet, and clamps, are adaptable to assembly line production layouts. Existing temporary devices, lacking a fixed clamping structure, are easily affected by the operating environment and operator techniques during mass production, leading to significant quality variations between batches. In this invention, the clamps stably hold the glass, and the closed molding chamber ensures consistent molding conditions for each mold set. This mold allows for simultaneous operation of multiple molds on a single production line. Existing temporary devices require manual adjustment of the frame and covering with a thin film, demanding high operator experience and prone to human error. In this solution, mold assembly only requires embedding a sealing gasket and glass, secured by clamps. Slurry infusion is completed automatically, requiring no specialized experience, reducing labor costs and lowering the operational threshold. This mold has a high-precision molding surface, ensuring sufficient flatness of the manufactured LSC surface, reducing light scattering and refraction losses caused by surface unevenness, and improving the LSC's light capture and transmission efficiency.

[0017] The main body of the mold of this utility model is made of polytetrafluoroethylene (PTFE). Utilizing its temperature resistance and chemical corrosion resistance, it avoids reaction with LSC slurry and can withstand temperature changes during the curing process. Furthermore, since the surface of the PTFE mold body is smooth and does not adhere to the LSC slurry, the finished product can be easily removed from the mold without the need for additional release agent, thus avoiding damage to the product surface. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the overall structure of a mold used to manufacture a light-emitting solar concentrator, according to an embodiment of this utility model.

[0019] Figure 2 This is an exploded view of a mold structure for manufacturing a light-emitting solar concentrator, as described in an embodiment of this utility model.

[0020] Figure 3 This is an isometric schematic diagram of the mold body in an embodiment of this utility model.

[0021] Figure 4 This is a schematic diagram of the clamp in an embodiment of the present utility model.

[0022] In the diagram, 1. Glass; 2. Sealing gasket; 3. Mold body; 4. Sealing cap; 5. Mounting groove; 6. Injection port; 7. Vent hole; 8. Chuck; 9. Shaft; 10. Fixture. Detailed Implementation

[0023] In the following description, only certain exemplary embodiments are briefly described. As those skilled in the art will recognize, the described embodiments can be modified in various ways without departing from the spirit or scope of this invention. Therefore, the drawings and description are considered exemplary in nature and not restrictive.

[0024] In the description of this utility model, it should be understood that the terms "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicating the orientation or positional relationship are based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this utility model and simplifying the description, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model.

[0025] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this utility model, "a plurality of" means two or more, unless otherwise explicitly specified.

[0026] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a communication connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0027] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0028] It should be understood that, when used in this specification and the appended claims, the terms "comprising" and "including" indicate the presence of the described features, integrals, steps, operations, elements and / or components, but do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components and / or collections thereof.

[0029] It should also be understood that the terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the scope of the invention. As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms unless the context clearly indicates otherwise.

[0030] It should also be further understood that the term "and / or" as used in this specification and the appended claims refers to any combination of one or more of the associated listed items and all possible combinations, and includes such combinations.

[0031] The accompanying drawings show various structural schematic diagrams according to embodiments of the present invention. These drawings are not to scale, and some details have been enlarged and may have been omitted for clarity. The shapes of the various regions and layers shown in the drawings, as well as their relative sizes and positional relationships, are merely exemplary and may deviate from reality due to manufacturing tolerances or technical limitations. Furthermore, those skilled in the art can design regions / layers with different shapes, sizes, and relative positions as needed.

[0032] See Figures 1 to 4 This utility model provides a mold for manufacturing a light-emitting solar concentrator, including a mold body 3. Glass 1 is embedded on both sides of the mold body 3 to form a closed molding chamber, providing molding space for LSC slurry and restricting the product shape. A pouring port 6 is provided at the top of the mold body 3, through which LSC slurry is poured into the closed molding chamber, serving as a channel for the slurry to enter the chamber. Several clamps 10 are provided on the side walls of the mold body 3. The clamps 10 are used to clamp the glass 1 on both sides of the mold body 3, ensuring a tight fit between the glass and the mold body through clamping force. It should be noted that the surface of the glass 1 must be highly flat and have a certain hardness to withstand the clamping force of the clamps.

[0033] In this embodiment, mounting grooves 5 are provided on the edges of the sides of the mold body 3. The sealing gasket 2 and the glass 1 are sequentially embedded in the mounting grooves 5. The mounting grooves 5 are used to position the sealing gasket 2 and the glass 1 to ensure accurate assembly.

[0034] In this embodiment, the number and size of the clamps 10 can be freely adjusted according to the actual situation, as long as the LSC slurry does not leak out. Furthermore, the clamps 10 should avoid clamping at the four corners of the glass 1 where stress is concentrated, and direct clamping at these positions should be avoided as much as possible. Alternatively, the glass 1 can be chamfered.

[0035] In some preferred embodiments of this invention, a sealing gasket 2 is provided between the mold body 3 and the glass 1 to fill the gap between them and prevent LSC slurry from leaking from the contact surface. Furthermore, the sealing gasket 2 should be as thin as possible; therefore, the thickness of the sealing gasket 2 is 0.1~0.3mm, otherwise it will affect the molding process.

[0036] See Figure 4 In some preferred embodiments of this utility model, the clamp 10 includes a clamp body and a chuck 8. The chuck 8 is connected to the clamp body via a pivot 9. The pivot 9 is designed so that the angle of the chuck 8 can be flexibly adjusted to ensure good contact with the surface of the glass 1. Furthermore, the chuck 8 is provided with an elastic buffer pad to avoid hard contact between the chuck 8 and the glass 1, and to prevent the glass 1 from being crushed or scratched.

[0037] The clamp body is equipped with an adjustment knob, which is connected to the rotating shaft 9. By rotating the adjustment knob, the clamping force of the chuck 8 on the glass 1 can be controlled, so as to achieve precise control of the clamping force and take into account both the sealing effect and the protection of the glass 1.

[0038] In some preferred embodiments of this utility model, the top of the mold body 3 is provided with an exhaust hole 7, which is used to discharge the air in the molding cavity during the LSC slurry pouring process, so as to avoid the residual air bubbles affecting the product quality.

[0039] In some preferred embodiments of this utility model, the injection port 6 is sealed by the sealing cap 4, which is used to seal the injection port 6 after the LSC slurry is injected, to prevent impurities from entering and the LSC slurry from evaporating.

[0040] In some preferred embodiments of this utility model, the mold body 3 is made of polytetrafluoroethylene, which utilizes its temperature resistance and chemical corrosion resistance to avoid reaction with LSC slurry and withstand temperature changes during the curing process.

[0041] When using this device: First, embed the sealing gasket 2 with a thickness of 0.1~0.3mm into the mounting groove 5 on the side of the mold body 3, and then embed the glass 1 into the mounting groove 5 in sequence. The mounting groove 5 uses physical limiting to ensure that the sealing gasket 2 and the glass 1 are precisely aligned and avoid displacement; the sealing gasket 2 fills the gap between the mold body 3 and the glass 1, and initially forms a leak-proof foundation; By rotating the adjustment knob on the fixture body, the rotating shaft 9 is driven to rotate, so that the chuck 8 fits against the glass surface until the appropriate clamping force is reached. At this time, the glass 1, the sealing gasket 2 and the mold body are tightly pressed together, finally forming a closed and leak-proof molding chamber, providing a stable space for subsequent LSC slurry filling.

[0042] Open the sealing cap 4 of the injection port 6 and slowly inject the prepared LSC slurry into the molding chamber through the injection port 6. As the LSC slurry fills, the air in the molding chamber will naturally escape through the vent 7 on the top of the mold body, preventing air from accumulating and forming air bubbles. Once the molding chamber is completely filled with LSC slurry, immediately seal the injection port 6 with the sealing cap 4: this prevents external dust and impurities from entering and contaminating the LSC slurry, and also prevents the volatile components in the LSC slurry from being lost before curing, which could lead to product shrinkage or performance degradation.

[0043] The completed mold is transferred to the curing equipment. Because the mold body 3 is made of polytetrafluoroethylene (PTFE), it possesses temperature and chemical corrosion resistance, allowing it to withstand temperature changes during curing without reacting chemically with the LSC slurry, thus preventing slurry deterioration or mold damage. During curing, the clamping force of the fixture 10 remains stable, ensuring no relative displacement between the glass and the mold body, preventing deformation of the molding chamber dimensions. The sealing gasket 2 continuously prevents leakage, preventing slurry leakage due to changes in state during curing, ultimately ensuring that the thickness, shape, and design of the LSC product are consistent.

[0044] After curing, reverse the operation of the clamp adjustment knob, loosen the clamp 8, remove the glass 1, and then take out the cured LSC product from the molding chamber of the mold body 3. Since the surface of the mold body 3 made of polytetrafluoroethylene is smooth and does not adhere to the LSC slurry, the finished product can be easily removed from the mold without the need for additional release agent, thus avoiding damage to the product surface.

[0045] The foregoing has shown and described the basic principles, main features, and advantages of this utility model. Those skilled in the art should understand that this utility model is not limited to the above embodiments. The embodiments and descriptions in the specification are merely preferred examples and are not intended to limit the utility model. Various changes and modifications can be made to this utility model without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claimed utility model. The scope of protection of this utility model is defined by the appended claims and their equivalents.

Claims

1. A mold for manufacturing a light-emitting solar concentrator, characterized in that, The mold body (3) includes a mold body (3) with glass (1) embedded on both sides to form a closed molding chamber. The top of the mold body (3) is provided with a pouring port (6), through which LSC slurry is poured into the closed molding chamber. Several clamps (10) are provided on the side wall of the mold body (3), and the clamps (10) are used to clamp the glass (1) on both sides of the mold body (3).

2. The mold for manufacturing a light-emitting solar concentrator according to claim 1, characterized in that, A sealing gasket (2) is provided between the mold body (3) and the glass (1).

3. A mold for manufacturing a light-emitting solar concentrator according to claim 2, characterized in that, The thickness of the sealing gasket (2) is 0.1~0.3mm.

4. A mold for manufacturing a light-emitting solar concentrator according to claim 2, characterized in that, The clamp (10) includes a clamp body and a chuck (8), and the chuck (8) is connected to the clamp body via a pivot (9).

5. A mold for manufacturing a light-emitting solar concentrator according to claim 2, characterized in that, The top of the mold body (3) is provided with an exhaust hole (7).

6. A mold for manufacturing a light-emitting solar concentrator according to claim 2, characterized in that, The filling port (6) is sealed by a sealing cap (4).

7. A mold for manufacturing a light-emitting solar concentrator according to claim 2, characterized in that, The mold body (3) is made of polytetrafluoroethylene.

8. A mold for manufacturing a light-emitting solar concentrator according to claim 2, characterized in that, The mold body (3) has mounting grooves (5) on the edge of its side, and the sealing gasket (2) and glass (1) are embedded in the mounting grooves (5) in sequence.

9. A mold for manufacturing a light-emitting solar concentrator according to claim 4, characterized in that, An elastic buffer pad is provided on the clamp (8).

10. A mold for manufacturing a light-emitting solar concentrator according to claim 4, characterized in that, The clamp body is provided with an adjustment knob, which is connected to the rotating shaft (9) for transmission. By rotating the adjustment knob, the clamping force of the chuck (8) on the glass (1) can be controlled.

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