Solar photovoltaic panel aluminum alloy support forming process

Abstract

Disclosed in the present invention is a solar photovoltaic panel aluminum alloy support forming process, which belongs to the technical field of photovoltaic supports. The process comprises: after an aluminum alloy profile is formed, pasting a protective film on a filling surface of the aluminum alloy profile, immersing same in a phosphating solution for phosphating treatment, then performing washing and drying, applying a fluorocarbon powder coating on an outer side surface and an inner side surface, removing the protective film, followed by performing baking, curing, and cooling, then immersing the aluminum alloy profile in an electrolytic solution for anodic oxidation, washing and drying same, and assembling the aluminum alloy profile into an aluminum alloy support, thereby completing the solar photovoltaic panel aluminum alloy support forming process. During the phosphating treatment, the filling surface is protected by pasting a protective film thereon, preventing the electric conductivity during anodic oxidation from being affected; the outer side surface and the inner side surface are coated with a fluorocarbon powder coating baking paint for curing, facilitating the production of a paint film with good antifouling performance and a good decorative effect; and the anodic oxidation of the filling surface facilitates an increase in the binding force of a silicone adhesive therewith, preventing debonding and separation after long-term use, and satisfying the use requirements for the solar photovoltaic panel.

Description

A forming process for an aluminum alloy bracket of a solar photovoltaic panel Technical Field

[0001] The present invention belongs to the technical field of photovoltaic brackets, and in particular relates to a forming process of an aluminum alloy bracket for a solar photovoltaic panel. Background Art

[0002] Solar photovoltaics refers to facilities that convert solar energy into direct current electricity using the photovoltaic effect of photovoltaic semiconductor materials. The core of a photovoltaic system is the solar panel, most of which are made primarily of silicon. However, due to their high production costs, their widespread use is limited. Compared to conventional batteries and rechargeable batteries, solar cells are more energy-efficient and environmentally friendly. However, due to their thinness, brittleness, and susceptibility to oxidation, they require protective packaging to form a stable solar cell module. The main structural components include tempered glass, EVA adhesive, cells, backplane, junction box, and aluminum alloy brackets.

[0003] Solar photovoltaic aluminum alloy brackets are specialized brackets designed and developed for the placement, installation, and securing of solar panels. They can be categorized as ground brackets, flat roof brackets, adjustable-angle roof brackets, sloped roof brackets, and column brackets. Aluminum alloy brackets are resistant to natural corrosion. Aluminum possesses excellent electrical conductivity and ease of processing, making them well suited to conducting the weak currents generated by various factors within photovoltaic bracket systems. They can be easily processed into desired specifications through sawing, drilling, punching, and folding. Aluminum profiles with varying cross-sectional shapes can be easily obtained through extrusion using different molds.

[0004] To ensure the waterproof performance of solar panels, the cells, backplanes and aluminum alloy brackets need to be coated with silicone glue after installation. However, in an exposed environment, these organic sealing materials will age and fail, especially easily separate from the aluminum alloy bracket, increasing the risk of damage to the solar photovoltaic components. Therefore, a solar photovoltaic panel aluminum alloy bracket forming process is proposed.

[0005] Summary of the Invention

[0006] The object of the present invention is to provide a solar photovoltaic panel aluminum alloy bracket forming process to solve the problems in the background technology.

[0007] The purpose of the present invention can be achieved through the following technical solutions:

[0008] A solar photovoltaic panel aluminum alloy bracket forming process includes the following steps:

[0009] Step 1: Place the aluminum alloy casting rod into a homogenizing furnace and keep it at 480-490℃ for 6-8h. Then take out the aluminum alloy casting rod and use water mist cooling to cool the aluminum alloy casting rod to room temperature at a cooling rate of 4.6-4.8℃ / min to complete the homogenization treatment of the aluminum alloy casting rod.

[0010] Step 2: The aluminum alloy cast rod after homogenization is heated to 465-470℃ in a high-frequency heating furnace, and then the heated aluminum alloy cast rod is extruded into an aluminum alloy profile using an aluminum alloy extrusion device. The aluminum alloy profile at the die mouth is directly towed by a traction machine, and the towed aluminum alloy profile is transferred to a cooling water tank and cooled to 30-50℃ to complete the forming process of the aluminum alloy profile.

[0011] During the aluminum alloy profile forming process, the specific settings for aluminum alloy cast rod extrusion forming are: die temperature of 470-480℃, extrusion speed of 2.5-3.5mm / s, and pulling speed of 2.5-3.8mm / s.

[0012] Step 3: Transfer the formed aluminum alloy profile to a heating furnace, keep it at 105-115℃ for 8-10h, then heat it to 145-155℃ and keep it for 6-8h, then naturally cool it to room temperature to complete the thermal aging treatment.

[0013] Step 4: Scald the aluminum alloy profile after heat aging treatment with 90-95℃ clean water for 2-3 times, then blow dry with a wind knife, immerse the aluminum alloy profile in degreasing cleaning agent and ultrasonically clean it for 10-20 minutes, take it out and wash it with clean water 1-2 times, then blow dry with a wind knife to complete the degreasing treatment.

[0014] Step 5: Paste the filling surface of the degreased aluminum alloy profile with a protective film, then immerse the aluminum alloy profile in phosphating solution, phosphating it at 25-30℃ for 20-30min, then wash it with clean water 2-3 times, blow it dry with an air knife, and then spray fluorocarbon powder coating on the outer and inner sides. After removing the protective film, bake it at 230-250℃ for 15-20min. After natural cooling, immerse the aluminum alloy profile in electrolyte, use the aluminum alloy profile as the anode, and anodize it at a voltage of 10-14V for 20-30min. Finally, wash it with clean water 2-3 times. After drying with an air knife, the surface protection treatment of the aluminum alloy profile is completed.

[0015] The electrolyte is a sulfuric acid solution with a mass concentration of 180-200g / L.

[0016] Step 6: Assemble the aluminum alloy profiles after surface protection treatment into an aluminum alloy bracket to complete the solar photovoltaic panel aluminum alloy bracket forming process.

[0017] Furthermore, the surface of the aluminum alloy profile includes an outer side surface, an inner side surface and a filling surface.

[0018] Furthermore, the model of the aluminum alloy cast rod is 6061-T6 but is not limited to 6061-T6.

[0019] Beneficial effects of the present invention:

[0020] The forming process of the solar photovoltaic panel aluminum alloy bracket of the present invention includes forming first, surface treatment and splicing. The surface treatment is carried out according to the use environment of the solar photovoltaic panel, which is conducive to obtaining an aluminum alloy bracket with good decorative and use effects.

[0021] Parameter optimization during the aluminum alloy profile forming process is conducive to obtaining better mechanical properties and meeting the strength requirements for the use of aluminum alloy brackets; during the phosphating treatment, the filling surface is protected by a protective film to prevent affecting the conductivity during anodizing. The outer and inner sides are sprayed with fluorocarbon powder coating and cured by baking paint, which is conducive to obtaining a paint film with good anti-fouling performance and decorative effect, and is conducive to increasing the texture of the aluminum alloy bracket. During anodizing treatment, the fluorocarbon paint film plays a good barrier role, and an oxide film is produced on the rest of the aluminum alloy. After anodizing treatment, the filling surface is conducive to increasing its bonding strength with the silicone adhesive, preventing debonding and separation after long-term use, and meeting the use requirements of solar photovoltaic panels. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The present invention will be further described below with reference to the accompanying drawings.

[0023] FIG1 is a flow chart of a forming process of an aluminum alloy bracket for a solar photovoltaic panel according to the present invention;

[0024] FIG2 is a schematic diagram of the cross-sectional structure of the aluminum alloy profile of the present invention.

[0025] In the figure: 1, outer side; 2, inner side; 3, filling side. DETAILED DESCRIPTION

[0026] The following will be combined with the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the embodiments described 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 making any creative efforts shall fall within the scope of protection of the present invention.

[0027] Example 1

[0028] Referring to Figures 1 and 2, this embodiment provides a solar photovoltaic panel aluminum alloy bracket forming process, including the following steps:

[0029] Step 1: Place the 6061-T6 aluminum alloy cast rod into a homogenizing furnace and keep it at 480°C for 6 hours. Then take out the aluminum alloy cast rod and use water mist cooling to cool it to room temperature at a cooling rate of 4.6°C / min to complete the homogenization treatment of the aluminum alloy cast rod.

[0030] Step 2: The homogenized aluminum alloy cast rod is heated to 465°C in a high-frequency heating furnace, and then the heated aluminum alloy cast rod is extruded into an aluminum alloy profile using an aluminum alloy extrusion device. The surface of the aluminum alloy profile includes an outer side surface 1, an inner side surface 2, and a filling surface 3 (see Figure 2). The aluminum alloy profile at the die mouth is directly towed by a traction machine, and the towed aluminum alloy profile is transferred to a cooling water tank and cooled to 30°C to complete the forming process of the aluminum alloy profile. The specific settings for the extrusion molding of the aluminum alloy cast rod are: the die mouth temperature is 470°C, the extrusion speed is 2.5mm / s, and the traction speed is 2.5mm / s.

[0031] Step 3: Transfer the formed aluminum alloy profile to a heating furnace, keep it at 105°C for 8 hours, then heat it to 145°C and keep it for 6 hours, and then naturally cool it to room temperature to complete the thermal aging treatment.

[0032] Step 4: After heat aging treatment, wash the aluminum alloy profile with 90°C clean water twice, then blow it dry with an air knife, immerse the aluminum alloy profile in a degreasing cleaning agent and ultrasonically clean it for 10 minutes. After taking it out, wash it with clean water once, and then blow it dry with an air knife to complete the degreasing treatment.

[0033] Step 5: Paste the filling surface 3 of the degreased aluminum alloy profile with a protective film, then immerse the aluminum alloy profile in phosphating solution, phosphate it at 25°C for 20 minutes, then wash it with clean water twice, blow it dry with an air knife, and then spray fluorocarbon powder coating on the outer side 1 and the inner side 2. After removing the protective film, bake it at 230°C for 15 minutes, and obtain a paint film with a thickness of 40±5μm after natural cooling. Immerse the aluminum alloy profile in an electrolyte, the electrolyte is a sulfuric acid solution with a mass concentration of 180g / L, use the aluminum alloy profile as the anode, and anodize it at a voltage of 10V for 20 minutes. Finally, wash it with clean water twice and blow it dry with an air knife to complete the surface protection treatment of the aluminum alloy profile.

[0034] Step 6: Assemble the aluminum alloy profiles after surface protection treatment into an aluminum alloy bracket to complete the solar photovoltaic panel aluminum alloy bracket forming process.

[0035] Example 2

[0036] Referring to Figures 1 and 2, this embodiment provides a solar photovoltaic panel aluminum alloy bracket forming process, including the following steps:

[0037] Step 1: Place the 6061-T6 aluminum alloy cast rod into a homogenizing furnace and keep it at 485°C for 7 hours. Then take out the aluminum alloy cast rod and use water mist cooling to cool it to room temperature at a cooling rate of 4.7°C / min to complete the homogenization treatment of the aluminum alloy cast rod.

[0038] Step 2: The homogenized aluminum alloy cast rod is heated to 468°C in a high-frequency heating furnace, and then the heated aluminum alloy cast rod is extruded into an aluminum alloy profile using an aluminum alloy extrusion device. The surface of the aluminum alloy profile includes an outer side surface 1, an inner side surface 2, and a filling surface 3 (see Figure 2). The aluminum alloy profile at the die mouth is directly towed by a traction machine, and the towed aluminum alloy profile is transferred to a cooling water tank and cooled to 40°C, completing the forming process of the aluminum alloy profile. The specific settings for the extrusion molding of the aluminum alloy cast rod are: the die mouth temperature is 475°C, the extrusion speed is 3mm / s, and the traction speed is 3mm / s.

[0039] Step 3: Transfer the formed aluminum alloy profile to a heating furnace, keep it at 110°C for 9 hours, then heat it to 150°C for 7 hours, and then naturally cool it to room temperature to complete the thermal aging treatment.

[0040] Step 4: After heat aging treatment, wash the aluminum alloy profile with 92°C clean water twice, then blow it dry with a wind knife, immerse the aluminum alloy profile in a degreasing cleaning agent and ultrasonically clean it for 15 minutes. After taking it out, wash it with clean water once, and then blow it dry with a wind knife to complete the degreasing treatment.

[0041] Step 5: Paste the filling surface 3 of the degreased aluminum alloy profile with a protective film, then immerse the aluminum alloy profile in phosphating solution, phosphate it at 28°C for 25 minutes, then wash it with clean water twice, blow it dry with an air knife, and then spray fluorocarbon powder coating on the outer side 1 and the inner side 2. After removing the protective film, bake it at 240°C for 18 minutes. After natural cooling, a paint film with a thickness of 40±5μm is obtained. The aluminum alloy profile is immersed in an electrolyte, and the electrolyte is a sulfuric acid solution with a mass concentration of 190g / L. The aluminum alloy profile is used as the anode and anodized at a voltage of 12V for 25 minutes. Finally, it is washed with clean water twice and blown dry with an air knife to complete the surface protection treatment of the aluminum alloy profile.

[0042] Step 6: Assemble the aluminum alloy profiles after surface protection treatment into an aluminum alloy bracket to complete the solar photovoltaic panel aluminum alloy bracket forming process.

[0043] Example 3

[0044] Referring to Figures 1 and 2, this embodiment provides a solar photovoltaic panel aluminum alloy bracket forming process, including the following steps:

[0045] Step 1: Place the 6061-T6 aluminum alloy cast rod into a homogenizing furnace and keep it at 490°C for 8 hours. Then take out the aluminum alloy cast rod and use water mist cooling to cool it to room temperature at a cooling rate of 4.8°C / min to complete the homogenization treatment of the aluminum alloy cast rod.

[0046] Step 2: The homogenized aluminum alloy cast rod is heated to 470°C in a high-frequency heating furnace, and then the heated aluminum alloy cast rod is extruded into an aluminum alloy profile using an aluminum alloy extrusion device. The surface of the aluminum alloy profile includes an outer side surface 1, an inner side surface 2, and a filling surface 3 (see Figure 2). The aluminum alloy profile at the die mouth is directly towed by a traction machine, and the towed aluminum alloy profile is transferred to a cooling water tank and cooled to 50°C, completing the forming process of the aluminum alloy profile. The specific settings for the extrusion molding of the aluminum alloy cast rod are: the die mouth temperature is 480°C, the extrusion speed is 3.5mm / s, and the traction speed is 3.8mm / s.

[0047] Step 3: Transfer the formed aluminum alloy profile to a heating furnace, keep it at 115°C for 10 hours, then heat it to 155°C and keep it for 8 hours, then naturally cool it to room temperature to complete the thermal aging treatment.

[0048] Step 4: After heat aging treatment, wash the aluminum alloy profile with 95°C clean water for 3 times, then blow it dry with an air knife, immerse the aluminum alloy profile in a degreasing cleaning agent and ultrasonically clean it for 20 minutes. After taking it out, wash it with clean water twice, and then blow it dry with an air knife to complete the degreasing treatment.

[0049] Step 5: Paste the filling surface 3 of the degreased aluminum alloy profile with a protective film, then immerse the aluminum alloy profile in phosphating solution, phosphate it at 30°C for 30 minutes, then wash it with clean water 3 times, blow it dry with an air knife, and then spray fluorocarbon powder coating on the outer side 1 and the inner side 2. After removing the protective film, bake it at 250°C for 20 minutes. After natural cooling, a paint film with a thickness of 40±5μm is obtained. The aluminum alloy profile is immersed in an electrolyte, and the electrolyte is a sulfuric acid solution with a mass concentration of 200g / L. The aluminum alloy profile is used as the anode and anodized at a voltage of 14V for 30 minutes. Finally, it is washed with clean water 3 times and blown dry with an air knife to complete the surface protection treatment of the aluminum alloy profile.

[0050] Step 6: Assemble the aluminum alloy profiles after surface protection treatment into an aluminum alloy bracket to complete the solar photovoltaic panel aluminum alloy bracket forming process.

[0051] Comparative Example 1: Based on Example 3 (reducing the anodizing time), the anodizing time was adjusted to 15 minutes, and the other steps remained unchanged to prepare an aluminum alloy bracket.

[0052] Comparative Example 2: Based on Example 3 (without phosphating treatment), the degreased aluminum alloy profile is immersed in an electrolyte, the electrolyte is a sulfuric acid solution with a mass concentration of 200g / L, and the aluminum alloy profile is used as the anode. Anodization is carried out at a voltage of 14V for 30 minutes, and finally washed with clean water 3 times. After being blown dry with an air knife, fluorocarbon powder coating is sprayed on the outer side 1 and the inner side 2. After removing the protective film, it is baked at 250°C for 20 minutes. After natural cooling, a paint film with a thickness of 40±5μm is obtained, and the aluminum alloy bracket is assembled.

[0053] Comparative Example 3: On the basis of Example 3 (no anodizing treatment), the degreased aluminum alloy profile is immersed in a phosphating solution, phosphating at 30°C for 30 minutes, then washed with clean water 3 times, blown dry with an air knife, and then sprayed with fluorocarbon powder coating on the outer side 1 and the inner side 2. After removing the protective film, it is baked at 250°C for 20 minutes, and naturally cooled to obtain a paint film with a thickness of 40±5μm, completing the surface protection treatment of the aluminum alloy profile. The aluminum alloy profiles after the surface protection treatment are assembled to obtain an aluminum alloy bracket.

[0054] The degreasing cleaning agent used in the above embodiments and comparative examples is a Kaimei brand environmentally friendly solvent-type cleaning agent purchased from Suzhou Haige Chemical Co., Ltd.; the phosphating liquid used is the HWJ-045 environmentally friendly phosphating liquid purchased from Guangdong Huiweijia Technology Co., Ltd.; the fluorocarbon powder coating used is a thermosetting powder coating purchased from Changshu Sanhui Paint Co., Ltd.

[0055] Performance tests were performed on Examples 1 to 3 and Comparative Examples 1 to 3. The paint film adhesion grades of the cured fluorocarbon powder coatings in Examples 1 to 3 and Comparative Examples 1 to 3 were determined in accordance with GB / T1720-2020 (grade 1 is the best and grade 7 is the worst). Different filling surfaces 3 were filled with silicone glue (purchased from Zhengzhou Sanbao Paint Co., Ltd.) and cured to obtain different samples. The samples were placed in deionized water at 55°C for accelerated aging for 2000 hours, and then the samples were removed and subjected to a 180° peel test. The results are shown in Table 1:

[0056] Table 1

[0057] As can be seen from Table 1, the fluorocarbon resin paint film and silicone adhesive in Examples 1 to 3 have good bonding strength with the corresponding parts of the aluminum alloy bracket. In Comparative Example 1, reducing the anodizing time will reduce the bonding strength between the silicone adhesive and the filling surface 3; in Comparative Example 2, the bonding strength level of the fluorocarbon resin sprayed after anodizing treatment is reduced because the oxide film will crack due to thermal stress during the paint baking process, resulting in a decrease in the bonding strength of the paint film; in Comparative Example 3, the bonding strength between the surface silicone adhesive and the phosphate layer is not as good as that of the anodized film layer.

[0058] It should be noted that, in this document, terms such as "comprises", "includes" or any other variations thereof are intended to cover non-exclusive inclusion, so that a process, method, article or apparatus that includes a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements that are inherent to such process, method, article or apparatus.

[0059] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A solar photovoltaic panel aluminum alloy bracket forming process, characterized in that: The steps include: Step 1: Wash the aluminum alloy profile after heat aging treatment 2-3 times, blow dry with air knife, immerse the aluminum alloy profile in degreasing cleaning agent and ultrasonically clean it for 10-20 minutes, take it out and wash it with clean water 1-2 times, and blow dry with air knife; Step 2: Paste a protective film on the filling surface (3) of the aluminum alloy profile, immerse it in a phosphating solution for phosphating treatment at 25-30° C. for 20-30 minutes, wash it 2-3 times and blow it dry with an air knife, then spray fluorocarbon powder coating on the outer side (1) and the inner side (2), remove the protective film and bake it at 230-250° C. for 15-20 minutes, immerse the aluminum alloy profile in an electrolyte after cooling, anodize it at a voltage of 10-14V for 20-30 minutes, wash it 2-3 times and blow it dry with an air knife; Step 3: Assemble the aluminum alloy profiles into an aluminum alloy bracket to complete the solar photovoltaic panel aluminum alloy bracket forming process.

2. A solar photovoltaic panel aluminum alloy bracket forming process according to claim 1, characterized in that: The electrolyte is a sulfuric acid solution with a mass concentration of 180-200 g / L.

3. A solar photovoltaic panel aluminum alloy bracket forming process according to claim 1, characterized in that: The specific method of the thermal aging treatment is as follows: The formed aluminum alloy profile is kept at 105-115°C for 8-10 hours, then heated to 145-155°C for 6-8 hours, and naturally cooled to room temperature to complete the thermal aging treatment.

4. A solar photovoltaic panel aluminum alloy bracket forming process according to claim 3, characterized in that: The specific method of the molding process is as follows: The aluminum alloy cast rod after homogenization is heated to 465-470°C and then extruded to obtain an aluminum alloy profile. The aluminum alloy profile at the die mouth is directly pulled by a traction machine into a cooling water tank and cooled to 30-50°C, completing the forming process of the aluminum alloy profile.

5. A solar photovoltaic panel aluminum alloy bracket forming process according to claim 4, characterized in that: During the aluminum alloy profile forming process, the specific settings for the aluminum alloy cast rod extrusion forming are: the die temperature is 470-480° C., the extrusion speed is 2.5-3.5 mm / s, and the pulling speed is 2.5-3.8 mm / s.

6. A solar photovoltaic panel aluminum alloy bracket forming process according to claim 4, characterized in that: The specific method of the homogenization process is as follows: The aluminum alloy cast rod is kept at 480-490°C for 6-8h, and then cooled to room temperature at a cooling rate of 4.6-4.8°C / min by water mist cooling to complete the homogenization treatment of the aluminum alloy cast rod.

7. A solar photovoltaic panel aluminum alloy bracket forming process according to claim 6, characterized in that: The model of the aluminum alloy cast rod is 6061-T6 but is not limited to 6061-T6.

Images