A composite material frame profile, solar energy module frame and its manufacturing method thereof
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Solution Overview
Problem
Composite material frame profiles used in solar energy modules have weak lateral strength, making quick plug-in connections with toothed corner connectors difficult due to mechanical clamping methods like interference fit or convex-concave fit.
Innovation Solution
A composite material frame profile with a plug-in cavity containing fiber fabric side walls and bumps or bosses that enhance mechanical strength, allowing for quick and secure connection with toothed corner connectors, where the bumps or bosses are reinforced with resin and designed with tapered holes to prevent cracking during punching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If mechanical clamping methods like interference fit or convex-concave fit are used for plug-in connection, then connection can be achieved, but lateral strength is weak and quick plug-in connection cannot be performed
Solution Approach 1:
The patent applies composite materials by embedding fiber fabric (such as glass fiber) within the plastic material of the frame profile, particularly concentrating fibers in the corner connector mounting area. This composite structure significantly enhances the lateral strength of the profile while maintaining the ability to perform quick plug-in connections with toothed corner connectors.
Solution Approach 2:
The patent implements local quality by selectively distributing fiber fabric within specific regions of the profile rather than uniformly throughout. The fiber concentration is increased in the corner connector mounting area where bumps or bosses are located, providing localized strength enhancement exactly where the plug-in connection occurs, without unnecessarily increasing the weight or complexity of the entire profile.
2Strength
If fiber fabric is added to enhance mechanical strength, then lateral strength and connection strength are improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the fiber fabric reinforcement with the existing plastic extrusion process. The fiber fabric is embedded within the plastic material during the extrusion成型 process, combining two manufacturing steps into one. This integrated approach enhances mechanical strength while avoiding the need for separate reinforcement installation steps, thereby controlling manufacturing complexity.
Solution Approach 2:
The patent utilizes parameter changes by controlling the distribution, orientation, and concentration of fiber fabric within the plastic matrix during extrusion. By adjusting these parameters (fiber orientation angles, fabric layer positioning, resin-to-fiber ratios), the mechanical strength can be optimized for specific load conditions while maintaining a relatively simple manufacturing process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution significantly enhances the mechanical strength of the corner connector mounting area, enabling quick and secure plug-in connections with toothed corner connectors, with a pulling force greater than 150 N, and simplifies the manufacturing process.
Implementation Method 1
The inner side wall of the plug-in cavity is a side wall containing a fiber fabric
Implementation Method 2
resin is infiltrated into the cavity of the through hole of each bump or boss, and the resin is cured to form a resin block
Implementation Method 3
protruding thorns or flanges distributed inwardly extending from the edge of the through hole
Implementation Method 4
mechanical clamping achieved through interference fit or convex-concave fit
Data Source
AI summary
Disclosed are a composite material frame profile, solar energy module frame and it's manufacturing method thereof, where the composite material frame profile includes a profile body and a plug-in cavity that is arranged on the profile body and is configured for plug-in connection with a toothed corner connector, a corner connector plug-in part is arranged on the inner surface of the side wall of the plug-in cavity in a corner connector mounting area of the frame profile, and the corner connector plug-in part can be a plurality of bumps or bosses; the side wall of the plug-in cavity is a side wall containing a fiber fabric; and the bumps or the bosses are configured for inserting and fixing the toothed corner connector. The mechanical strength of the corner connector mounting area of the frame profile can be well enhanced through fiber fabrics, so that the mechanical strength of the bumps or the bosses is enhanced, and the quick plug-in connection with the toothed corner connector is realized.