Structure Design And Injection Molding Process Of Plastic Photovoltaic Module

Photovoltaic (PV) module is the key equipment in solar power systems. So far, there are some problems in the PV module made of aluminum alloy or stainless steel. The manufacturing cost is high and the installation process is complicated. Moreover, problems like electrochemical corrosion are likely to emerge during the service life. The PV module made of plastics is rare in the domestic market compared to the ones made by metal. The manufacturability, insulating property and corrosion resistance of engineering plastics are very good. The P V module made of engineering plastics can avoid the problems above. In this thesis, a special structure of novel PV module made of fiber-reinforced polypropylene (FRPP) is described, followed by the systematic mechanical analysis of the structure, the research of the injection molding process and the design of injection mould.The developments of the PV module in the domestic and abroad are introduced, including the types of loads on the PV module during service life, some forms of PV module which are mainly building integrated PV applications and some development of materials which are used for the PV module abroad. Then the methods of the structure design and manufacture are introduced as well as their theoretical basis.The geometries of the PV module are described. The sizes and the material used are both determined. According to the Load Code for the Design of Building Structures(GB50009-2012) and Photovoltaic Power Station Design Specification(GB50797-2012), the types of loads involved in the practical occasion of PV module are determined. The governing formulas and values of loads adopted in the strength check and rigidity check are determined. The mechanical analyses of PV module structure are conducted by the software ANSYS Workbench. It turns out that the strength and rigidity of the proposed design both meet the requirement of the standards above.The numerical calculations of the injection molding process of solar stent are carried out by the software Moldflow. The feed system, cooling system and the initial injection molding process parameters are optimized according to the simulation results of the fill time, average shrinkage ratio, air trap location, weld line location, warpage. The warpage is reduced by optimizing the holding pressure. It turns out that the injection molding processing property of the specific solar stent performs well. The warpage can be reduced by optimization of holding pressure.The designs of cavity/core, feed system, injection mold base, cooling system are successively conducted by IMOLD, making the whole structure of injection mold of solar stent. This method cuts down the cost and development cycle of the solar stent compared with the traditional mold design method.