Composite PV Frame Pultrusion Upgrade in China

Illustration notice. Process illustrations are not verified photographs of this installation.

Project reference basis. Figures and configuration details are reported in the supplied project brief. They are reference values for the stated application, rather than verified acceptance results or a guarantee for another installation. Confirm the source records, material, tooling, operating schedule and test method when assessing a comparable project.

Project configuration and outcomes described in the supplied project brief.

A leading tier-one solar module component manufacturer deployed Haifeng’s automated closed direct-injection pultrusion technology to upgrade its composite photovoltaic frame manufacturing facilities. The project targeted replacing conventional aluminum frame extrusion lines with an advanced, non-corrosive polyurethane fiberglass composite framing process.

Before the upgrade, the customer's experimental pultrusion line utilized open liquid resin baths. This setup suffered from erratic wet-out at line speeds above 0.8 m/min, resulting in internal voids exceeding 3.5% and frequent resin gelation skinning, which required frequent line shutdowns and caused hazardous workshop fumes.

Haifeng supplied an integrated direct-injection package centered on the HF-PVI-40H system. By docking the high-pressure impingement mixing head directly to a sealed die injection chamber, the supplied brief reports processing of 80% fiber-volume bundles at 1.2 m/min. Frame/profile results and solar-module qualification are assessed separately.

Equipment configuration reported in the supplied project brief.

Haifeng engineered a fully enclosed resin delivery and wet-out system integrated into the customer’s existing multi-cavity pultrusion line. Raw polyol and isocyanate are stored in dual-jacketed stainless steel vessels with dry nitrogen blankets to prevent moisture-induced foaming.

The chemical components are accurately displaced by servo-driven high-pressure axial piston pumps. Continuous mass flow signals dynamically synchronize with the pultrusion haul-off drive, maintaining stoichiometric consistency within ±0.3% during line acceleration and deceleration.

The chemicals impinge at 12.0 MPa within the die-mounted mixing head and discharge directly into the sealed injection die box. The fast-reacting polyurethane is forced deep into dense bundles of continuous roving (4800tex) under 1.5 MPa hydraulic die backpressure. The saturated profile cures through three progressive electric die heating zones (160°C to 195°C) before passing through automated inline cutting saws for palletizing.