HK1162404A - Solar energy lens multi-cavity ejection to mode method - Google Patents

Description

Multi-cavity injection molding method for solar lens

Technical Field

The invention relates to a manufacturing method of a solar lens, in particular to a multi-cavity injection molding method of the solar lens.

Background

As petroleum resources are exhausted, various alternative energy sources, such as solar energy, wind power, water power, geothermal energy, etc., are generated, and solar energy has characteristics of being less limited by regions, stability, pollution-free, inexhaustible, etc., and is one of alternative energy sources which are researched by various countries, so that various architectures or ways of converting solar energy into energy types required by human beings are generated, one of which is a so-called concentrating solar cell which converts solar energy into electric power.

The concentrating solar cell mainly comprises a group of solar wafer modules and a group of solar lenses arranged above the solar wafers, wherein the solar lenses comprise Fresnel lenses, so that sunlight is focused on the solar wafers by means of the Fresnel lenses to improve the power generation efficiency.

The fresnel lens is initially prepared by molding acrylic material with four cavities, but the exposed acrylic fresnel lens has the problems of impact resistance, yellowing, deterioration, scratch caused by dust, and the like besides the problems of difficult control of molding conditions, stress, uneven thickness, and the like.

Therefore, another way of manufacturing the fresnel lens made of acrylic material is to adhere the fresnel lens to the glass surface with an adhesive, but it still has the following disadvantages:

1. the bonding time of the glass and the lens is too long, and bubbles are easy to generate;

2. the relative position of each lens is not easy to control;

3. because the position of the lens is not easy to control, the solar wafer below needs to be correspondingly adjusted with respect to the lens, which is time-consuming;

4. after the lens and the glass are adhered, the glass needs to be baked in an oven, so that the whole manufacturing time is too long.

In view of the above, the present invention provides a method for multi-cavity injection molding of a solar lens to overcome the above problems.

Disclosure of Invention

The main objective of the present invention is to provide a method for multi-cavity injection molding of solar lens, which forms a plurality of lenses on the surface of a glass substrate by using an insert injection molding method in a single process, so as to effectively shorten the process time and improve the accuracy of lens alignment.

Another object of the present invention is to provide a method for multi-cavity injection molding of solar lens, which has anti-yellowing, anti-uv and anti-impact properties.

To achieve the above object, the present invention provides a method for multi-cavity injection molding of a solar lens, comprising the steps of: firstly, providing a mould set which comprises a female mould and a male mould corresponding to the female mould, wherein the female mould is provided with an accommodating groove, the male mould is provided with a plurality of lens mould cavities with lens lines, and each lens mould cavity is connected with a cold runner; then, placing a glass substrate in the accommodating groove; then, injecting a silica gel material into the lens mold cavity through each cold pouring channel; finally, the mold set is heated to solidify the silica gel material, so as to form a plurality of silica gel lenses on the surface of the glass substrate.

In summary, the present invention provides a method for multi-cavity injection molding of solar lens, so as to rapidly and massively prepare solar lens with good alignment and excellent environmental resistance.

The purpose, technical content, features and effects of the present invention will be more readily understood through the detailed description of the specific embodiments.

Drawings

FIG. 1 is a flow chart of the steps of the present invention;

FIG. 2 is a schematic diagram of a mold configuration used in the present invention;

fig. 3 is a schematic cross-sectional structure diagram of a solar lens manufactured by the invention.

Description of reference numerals: 10-a mould set; 12-a master mould; 14-male mold; 16-a receiving groove; 18-a lens cavity; 20-cold pouring channel; 22-a glass substrate; 24-lens.

Detailed Description

The invention discloses a multi-cavity injection molding method of a solar lens, which utilizes an embedding injection molding mode to form a plurality of lenses on the surface of a glass substrate in a single process so as to effectively solve the defects of the prior art such as long process time, poor lens alignment and the like.

In addition, in the aspect of selecting the lens material, the invention uses the silica gel material as the material of the lens, so that the lens achieves the characteristics of yellowing resistance, ultraviolet resistance, impact resistance and the like by virtue of the characteristics of the silica gel material.

Please refer to fig. 1 and fig. 2, which are a flowchart illustrating steps of the present invention and a schematic diagram illustrating a mold structure used in the present invention. As shown in the figure, firstly, as shown in step S1, a mold set 10 is provided, which includes a female mold 12 and a male mold 14 corresponding to the female mold 12, the female mold 12 has a receiving groove 16, the male mold 14 has a plurality of lens mold cavities 18 with lens patterns, each lens mold cavity 18 corresponds to the receiving groove 16 and is connected to a cold runner 20, wherein the lens patterns are fresnel lens patterns; next, as shown in step S2, a glass substrate 22, such as tempered glass, is placed in the receiving groove 16, and the female mold 12 and the male mold 14 are closed; as shown in step S3, a silicone compound is injected into the lens cavity 18 through each cold runner 20, wherein the machine injection stroke is 250 millimeters (mm), the injection rate is 143 centimeters per second (cm/sec), and the maximum injection pressure is 479 kilograms per centimeter per second squared (kg/cm sec)²) (ii) a And heating the mold set 10 to cure the silicone gel material as described in step S4 to form a plurality of silicone gel lenses 24 on the surface of the glass substrate 22 for use as solar mirrors, as shown in fig. 3. After the fabrication, the glass substrate 22 can be taken out by a robot from the other surface thereof in a sucking manner to avoid damage to the silicone lens.

Before the glass substrate is placed in the containing groove, an interface adhesive which is a mixture of organic silicon functional groups is coated on the surface of the glass substrate to increase the adhesion between the silica gel and the glass substrate.

Furthermore, since the silica gel used in the present invention is a pre-heat hardening material, a cooling device and a heating device are disposed at the male mold end, so that the temperature of the male mold can be maintained at room temperature (for example, about 23 ℃) as required when injecting the silica gel material, and after the injection is completed, the male mold is heated for curing, and the temperature during curing is about 100 ℃ to 200 ℃. The female mold end is provided with a heating device to properly adjust the temperature of the mold set and adjust the temperature of the glass substrate as required, so that the silica gel material contacting the glass substrate can be cured first, and the overall process time is shortened. The overall process time is about 60 seconds complete and the cycle time is about 3 minutes.

In addition, a needle valve can be arranged in the cold pouring gate, so that the cold pouring gate can be automatically closed when the glue injection is finished, and the backflow of the glue material is avoided. In addition, the male mold end may further be provided with a vacuum pumping device connected to the lens mold cavity to facilitate injecting the silicone compound into the lens mold cavity, wherein the final pressure of the vacuum pumping device to the vacuum pumping pressure range of the lens mold cavity is 0.1 hectopar (hpa).

The number of the lens cavities of the male mold can be adjusted according to the process requirements, such as the pause number or the pressure of a machine and other parameters, so as to achieve the purposes of rapid production and stable manufacturing. The fixed tolerance of each lens cavity can reach 0.2 millimeters (mm).

In summary, the present invention provides a method for multi-cavity injection molding of solar lens, so as to rapidly and massively prepare solar lens with good alignment and excellent environmental resistance.

The above description is only a preferred embodiment of the present invention, and is not intended to limit the scope of the present invention. Therefore, all the equivalent changes or modifications according to the features and the spirit of the claims should be included in the claims of the present invention.

Claims (10)

1. A multi-cavity injection molding method for a solar lens is characterized by comprising the following steps:

step 1: providing a mold set, which comprises a female mold and a male mold corresponding to the female mold, wherein the female mold is provided with an accommodating groove, the male mold is provided with a plurality of lens mold cavities with lens lines, and each lens mold cavity is connected with a cold runner;

step 2: placing a glass substrate in the accommodating groove;

and step 3: injecting a silicone material into the lens mold cavity through each cold runner; and

and 4, step 4: and heating the mold set to solidify each silica gel material to form a plurality of silica gel lenses on the surface of the glass substrate.

2. The method of claim 1, wherein the step of coating an interface adhesive on the surface of the glass substrate before placing the glass substrate in the receiving cavity.

3. The method of claim 1, wherein the step 3 is performed at room temperature.

4. The method for multi-cavity injection molding of solar lens as claimed in claim 1, wherein the heating in step 4 is at a temperature of 100-200 ℃.

5. The method of claim 4, wherein the female mold has a heating function and the male mold has a cooling and heating function.

6. The method of claim 1, wherein the lens pattern of the lens cavity is a fresnel lens pattern.

7. The method of claim 1, wherein the male mold further comprises a vacuum device connected to the lens cavity to facilitate injection.

8. The method of claim 7, wherein a final pressure of the evacuation device to the evacuation pressure range of the lens cavity is 0.1 kpa.

9. The method of claim 1, wherein the silicone gel material is injected at an injection rate of 143 cm/s and an injection maximum pressure is 479 kg/cm/s squared.

10. The method of claim 2, wherein the interface gel is a mixture of silicone functional groups.