Solar Panel Frame

[entrack]

We are designing a portable LED light that comes with a solar panel, the dimension for the frame is 70x120mm. What would be the suitable material for the solar panel frame for the expected life span of 5 years?
The part is exposed to sun all day so UV resistant is a must.
Product market is Africa so cost is important. Tks

 

[Pud]

uPVC (if you are in the US, I think it's called vinyl?)

There are a few suitable materials but I would guess uPVC will be the cheapest. You might have a look at extruded sections (low tooling cost but fabrication costs up) to make a frame from, although a one-piece moulding will look better...

H

www.tynevalleyplastics.co.uk

It's ok to soar like an eagle, but weasels don't get sucked into jet engines.

 

[patprimmer]

Before daring an answer, my questions are.

Is it a complex shape that might be prone to warping during the moulding process?

Will it involve any rough handling?

Will it be under any noticable mechanical load?

I know leds run relatively cool, but they still generate some heat. Do you have any idea what the maximum point temperature might be?

What surface finish is required?

Is decoration or printed on labeling required?

If the temperatures are as low as one might expect, Pud has made a good suggestion.

Other possibilities depending on the above parameters are filled PP, PC, ASA, GF or unfilled versions of Nylons or polyesters.

Tooling costs/number of parts over time and cycle times in moulding will have as much influence on final costs as the raw material chosen. They do vary significantly with different materials.

Regards
Pat
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[entrack]

Hi Pud,


Thank you for your suggestion, the part resembles a photo frame, I have attached the picture and we use screws to assemble the top and the bottom part together. The frame or it is better to say the housing for the solar panel is small, 70x120mm so I also think one piece molding is better and cheaper.I will be looking into uPVC, thanks

 

[entrack]

Hi Pat,

Thanks for your reply.
The question is on the material for the solar panel housing, the dimension for the panel housing is 70mmx120mm. I have attached a picture of it, it very much resembles a photo frame. One option is use aluminum frame but aluminum cost is not low either and our panel is too small to use aluminum frame also.

I am in China and Aluminum cost here is about 3.54 USD per Kg and ASA is about 5.72 USD per Kg but considering specific gravity then ASA seems to be cheaper than aluminum for this part but I am still looking for lower cost alternatives in plastics. As for the injection fees, they are not that high here, it is about 0.12 USD for this part.

The LED lamp is a separate part.
below the answers:

Is it a complex shape that might be prone to warping during the moulding process? No

Will it involve any rough handling? No

Will it be under any noticable mechanical load? No

I know leds run relatively cool, but they still generate some heat. Do you have any idea what the maximum point temperature might be? The LED lamp is a separate part and is not affecting the solar panel, the solar panel housing is exposed to the sun all day and the temperature on the panel could reach 70 degree C , (158F)

What surface finish is required? smooth or textured, no specific requirements.

Is decoration or printed on labeling required? no decoration but a logo might be needed which could be done on the tooling I assume

If the temperatures are as low as one might expect, Pud has made a good suggestion,
Tks,