Modular integrated photovoltaic roadway assembly

Abstract

This invention discloses a modular integrated photovoltaic road component, belonging to the field of road engineering. The invention includes a photovoltaic power generation unit, a roadbed, a load-bearing heat dissipation module panel, and an electrically controlled dimming film. The load-bearing heat dissipation module panel includes a load-bearing panel, a honeycomb sandwich structure, and a sealed heat dissipation plate. The top and bottom of the honeycomb sandwich structure are respectively connected to the load-bearing panel and the sealed heat dissipation plate. The photovoltaic power generation unit is fixedly installed inside the honeycomb sandwich structure. The bottom surface of the load-bearing heat dissipation module panel is fixedly installed to the top surface of the roadbed. An electrically controlled dimming film is provided inside the load-bearing panel. A lighting component is provided between the photovoltaic power generation unit and the load-bearing panel. The sides of every two adjacent load-bearing heat dissipation module panels are modularly spliced. This invention, through the modular design of the load-bearing heat dissipation module panel, ensures product consistency and high reliability, greatly improves construction efficiency, and simplifies replacement and maintenance.

Description

Technical Field

[0001] This invention relates to the field of road engineering, and in particular to a modular integrated photovoltaic road component. Background Technology

[0002] With the increasing global demand for renewable energy, solar photovoltaic technology is being widely explored for application in various infrastructure projects. The concept of "photovoltaic roads" aims to transform a vast road network into a distributed energy collection platform, achieving resource utilization without additional land occupation, and has attracted global attention. From the early concept of Solar Roadways in the United States in 2009, to demonstration projects such as the SolaRoad solar bike path in the Netherlands in 2014 and the Wattway solar highway in France in 2016, and finally to the world's first load-bearing highway photovoltaic pavement test section opened in Jinan, Shandong, China in 2017, this technology has moved from proof of concept to engineering practice and has initially demonstrated potential functions such as power generation and snow melting.

[0003] However, these existing and publicly available technical solutions have revealed a series of systemic bottlenecks and contradictions in the process of moving towards large-scale commercial application, as follows: 1. The inherent contradiction between single function and performance interlocking: Existing photovoltaic road modules are essentially still "passive" power generation panels with a single function. To protect the photovoltaic cells and meet the stringent requirements of vehicle load-bearing capacity, thickened tempered glass or high-strength resin protective layers must be used, but this leads to severe light transmittance loss, especially with extremely low utilization efficiency of low-angle sunlight in the early morning and late evening. More importantly, power generation performance and road safety performance are mutually restrictive: to increase power generation, dark or high-absorption surfaces are often used, but this reduces road surface reflectivity, which is detrimental to driving safety; while increasing surface roughness to ensure anti-skid performance will aggravate light scattering, further reducing power generation efficiency. This mutual constraint between optical and mechanical performance has become the core obstacle to improving the overall system efficiency.

[0004] 2. Insufficient heat dissipation and long-term reliability challenges: Photovoltaic cells generate a large amount of heat during operation. However, traditional road materials or encapsulation structures have low thermal conductivity, causing heat to accumulate in the cell layers, leading to a severe "hot spot effect" and accelerating cell power decay and aging. At the same time, the cyclic coupling of vehicle dynamic load and thermal stress can easily cause fatigue cracking of encapsulation materials and electrical connection failure, making maintenance extremely difficult.

[0005] 3. Lack of modularity and maintainability: Existing technologies mostly adopt monolithic or large-panel installations, lacking standardized modular designs that support factory prefabrication and rapid on-site assembly. Local damage often necessitates large-scale dismantling and repair, resulting in high costs and prolonged traffic disruptions. Electrical connections also largely rely on manual on-site wiring, leading to low reliability and difficulty in achieving plug-and-play functionality and flexible expansion of the system.

[0006] In response to the aforementioned complex technical challenges, including single function, performance interlocking, and difficult maintenance, this invention designs a modular integrated photovoltaic road component. Summary of the Invention

[0007] The purpose of this invention is to provide a modular integrated photovoltaic road module that can solve the problems of single function, performance interlocking, and difficult maintenance mentioned above.

[0008] To solve the above-mentioned technical problems, the present invention is achieved through the following technical solution: This invention relates to a modular integrated photovoltaic road component, comprising a photovoltaic power generation unit, a roadbed, a load-bearing heat dissipation module panel, and an electronically controlled dimming film, which constitutes a basic functional unit integrating power generation, lighting display, and load bearing. The load-bearing heat dissipation module panel includes a load-bearing panel, a honeycomb sandwich structure, and a sealed heat dissipation plate, forming a high-strength, lightweight, and heat-conducting composite support structure. The top and bottom of the honeycomb sandwich structure are respectively connected to the load-bearing panel and the sealed heat dissipation plate. A photovoltaic power generation unit is fixedly installed inside the honeycomb sandwich structure; the bottom surface of the load-bearing heat dissipation module plate is fixedly installed to the top surface of the roadbed; it provides a stable mounting base for the photovoltaic power generation unit and is connected to the road foundation. An electrically controlled dimming film is installed inside the supporting panel; a lighting component is installed between the photovoltaic power generation unit and the supporting panel; the lighting component is located in the non-light-receiving area on the side or above the photovoltaic power generation unit. It achieves intelligent switching of the road surface optical state through the electrically controlled dimming film and arranges the lighting component to avoid obstructing photovoltaic power generation. Modular splicing is performed between the sides of each pair of adjacent load-bearing heat dissipation module plates, enabling rapid paving, partial replacement, and convenient maintenance of the entire road surface.

[0009] As a preferred embodiment of the present invention, the bearing panel is made of polycarbonate material, and the top surface of the bearing panel is coated with an ultra-wear-resistant self-cleaning layer; the ultra-wear-resistant self-cleaning layer is a transparent microcrystalline ceramic coating prepared by sol-gel method, and its surface Mohs hardness is ≥8; the ultra-wear-resistant self-cleaning layer is bonded to the electronically controlled dimming film through a polyurethane elastomer film, and the electronically controlled dimming film is located below the ultra-wear-resistant self-cleaning layer; this ensures that the road surface has extremely high wear resistance and anti-skid performance, while protecting the underlying electronically controlled dimming film and achieving optical coupling.

[0010] As a preferred technical solution of the present invention, it includes an existing microprism array, which includes a microlens structure and an optical waveguide structure; the lower surface of the supporting panel is precisely imprinted with the microprism array according to the road orientation and latitude and longitude information of the road section, and the microprism array is located below the electronically controlled dimming film. The microprism array is used to refract low-angle incident sunlight so that it is directed more vertically towards the photovoltaic power generation unit below; it improves the utilization rate of low-angle sunlight in the early morning and evening, thereby increasing the total power generation of the photovoltaic power generation unit throughout the day.

[0011] As a preferred embodiment of the present invention, the electro-dimming film is a polymer-dispersed liquid crystal film or a solid electrochromic film; when no voltage is applied to the electro-dimming film, the electro-dimming film is in a scattering state and enters a scattering lighting mode; when a specific voltage is applied to the electro-dimming film, the electro-dimming film quickly switches to a transparent state and enters a light-transmitting power generation mode; thus realizing rapid and reversible switching between the two working modes of active light-emitting illumination and high-efficiency light-transmitting power generation of the road surface.

[0012] As a preferred embodiment of the present invention, the honeycomb sandwich structure is made of 6061-T6 aluminum alloy manufactured by extrusion molding process. Its interior is a regular hexagonal honeycomb core structure, and the diameter of the inscribed circle of each cell ranges from 5mm to 30mm. The surface of the honeycomb sandwich structure is provided with a reflective layer. While ensuring extremely high structural strength, it provides a large area of ​​contact heat dissipation surface for internal components, and reflects light to the bottom of the photovoltaic power generation unit through the reflective layer to improve power generation efficiency.

[0013] As a preferred embodiment of the present invention, a silicone gasket is fixed between the top surface of the sealing heat sink and the bottom surface of the photovoltaic power generation unit; the sealing heat sink is made of polycarbonate material and filled with ceramic powder; a heat-conducting sheet is provided below the silicone gasket on the sealing heat sink; the heat generated by the photovoltaic power generation unit is efficiently conducted out through the silicone gasket and the heat-conducting sheet to the outside of the sealing heat sink and dissipated, while ensuring the sealing of its bottom.

[0014] As a preferred embodiment of the present invention, the lighting component adopts a flexible LED panel with an emission spectrum of 500nm to 700nm, and each flexible LED panel is fixedly connected to the inner wall of the honeycomb sandwich structure; it provides an efficient and uniform lighting or display light source, and its emission spectrum matches the spectral response peak of the photovoltaic power generation unit, which facilitates the efficient recovery and utilization of internal light energy.

[0015] As a preferred embodiment of the present invention, the load-bearing heat dissipation module plate adopts a stacked rectangular module structure; a male tenon and a female mortise are respectively provided between the sides of each two adjacent load-bearing heat dissipation module plates; each two adjacent load-bearing heat dissipation module plates are modularly spliced ​​together by the male tenon and the female mortise; thus achieving precise mechanical positioning and reliable physical connection between adjacent modules.

[0016] As a preferred technical solution of the present invention, it includes a battery pack; the photovoltaic power generation unit charges the battery pack through a charging controller; the male and female ends of a blind-fit electrical connector are respectively provided on the male tenon and female mortise; the blind-fit electrical connector includes a power bus and a data communication bus, the battery pack wires are connected to the power bus, the battery pack supplies power to each component through the power bus, and the data communication bus forms a communication network for each component; it realizes automatic and rapid electrical and signal connection between adjacent modules, forming a distributed power supply and communication network.

[0017] As a preferred embodiment of the present invention, a temperature sensor and a light intensity sensor are fixedly installed inside the heat dissipation module plate, and a pressure sensor is fixedly installed between the heat dissipation module plate and the roadbed. The temperature sensor, light intensity sensor, and pressure sensor are all electrically connected to a microprocessor, and the microprocessor is electrically connected to an electronically controlled dimming film. A main controller is fixedly installed in each section of the roadbed, and each microprocessor is electrically connected to a main controller via a data communication bus. It monitors the working status and environmental parameters of each module in real time, and the main controller performs centralized processing and intelligent control to realize automatic switching of working modes according to ambient light, temperature, or traffic pressure.

[0018] The present invention has the following beneficial effects: 1. This invention integrates photovoltaic power generation units, electronically controlled dimming films, lighting components, and necessary load-bearing and heat dissipation structures into a standardized and modular structural unit design using a load-bearing heat dissipation module plate. Rapid expansion is achieved through the splicing design on the side of the module. This integrates the previously fragmented power generation, load-bearing, and optical functions of traditional photovoltaic pavements into a basic module that can be prefabricated in the factory and assembled on-site, providing a physical carrier for building intelligent and easily maintained road systems. It offers advantages such as ensuring product consistency and high reliability, significantly improving construction efficiency, and simplifying replacement and maintenance.

[0019] 2. Through the function of the electronically controlled dimming film, the photovoltaic road can switch modes according to the ambient light and traffic demand, realizing the dynamic coordination and on-demand switching of power generation, lighting and information display; it has the advantages of integrating power generation, lighting and information display, and greatly improving the functional value and utilization efficiency of a single physical space.

[0020] 3. This invention utilizes an integrated load-bearing heat dissipation module plate. Its composite "sandwich" structure, consisting of a load-bearing panel, a honeycomb sandwich structure, and a sealed heat dissipation plate, provides a high-strength mounting platform and pre-designed heat dissipation channels for photovoltaic power generation units and lighting components. The honeycomb sandwich structure also provides excellent compressive and shear resistance, while its large internal surface area constitutes a highly efficient heat dissipation surface. Combined with the sealed heat dissipation plate, this forms an efficient heat conduction path from the heat source to the outside environment, thereby ensuring the long-term operational reliability and lifespan of core electronic components under vehicle loads. It boasts advantages such as high strength, efficient heat conduction, and improved operational reliability and lifespan. Attached Figure Description

[0021] Figure 1 A schematic diagram of modular installation of a modularly integrated photovoltaic road component provided by the present invention; Figure 2 A top view of the modular installation of a modularly integrated photovoltaic road component provided by the present invention; Figure 3 This is a schematic diagram of the structure of the heat dissipation module board and the female part provided by the present invention; Figure 4 This is a structural schematic diagram of the heat dissipation module plate and tenon provided by the present invention; Figure 5 This is a schematic diagram of the honeycomb sandwich structure, photovoltaic power generation unit, and lighting component provided by the present invention. Figure 6 This is a cross-sectional view of the internal stacked structure of a modular integrated photovoltaic road module provided by the present invention.

[0022] Explanation of reference numerals in the attached figures: 1. Photovoltaic power generation unit; 2. Roadbed; 3. Load-bearing heat dissipation module plate; 4. Electronically controlled dimming film; 5. Lighting component; 301. Load-bearing panel; 302. Honeycomb sandwich structure; 303. Sealed heat dissipation plate; 3031. Silicone gasket; 3032. Thermal conductive sheet; 304. Tenon; 305. Tenon. Detailed Implementation

[0023] The specific embodiments of the present invention will be described in detail below, but it should be understood that the scope of protection of the present invention is not limited to the specific embodiments.

[0024] like Figures 1 to 5 As shown in the figure, the modular integrated photovoltaic road module provided by this embodiment of the invention has standard single-piece dimensions that can be designed into three models according to the road load level: the first model is 1000mm long, 500mm wide, and 100mm thick; the second model is 800mm long, 600mm wide, and 60mm thick; and the third model is 500mm long, 500mm wide, and 40mm thick. Figure 6 As shown, it includes a photovoltaic power generation unit 1, a roadbed 2, a load-bearing heat dissipation module 3, an electronically controlled dimming film 4, and a lighting component 5.

[0025] Among them, such as Figure 1 and Figure 6 As shown, taking the first model as the design standard, the heat dissipation module plate 3 is the core supporting structure. Its supporting panel 301 is made of 10mm thick transparent polycarbonate sheet, with a transparent microcrystalline ceramic ultra-wear-resistant self-cleaning layer with a Mohs hardness of 9 coated on the top surface. This layer gives the road surface excellent anti-slip, wear-resistant, and self-cleaning properties. The lower surface of the supporting panel 301 is precisely imprinted with an isosceles triangular microprism array with a period of 50μm and a apex angle of 110°, according to the latitude and longitude of the installation section, such as 30° North latitude and east-west direction. The function of this microprism array is to refract low-angle sunlight in the early morning and late evening, making it more vertically incident, thereby increasing the daily power generation of the photovoltaic power generation unit 1 by approximately 15%. Below the microprism array, a layer of polymer-dispersed liquid crystal (PDLC) material electro-dimming film 4 is bonded to the surface via a polyurethane elastomer film. The function of this electro-dimming film 4 is to achieve controllable switching of the road surface's optical state. Below the supporting panel 301, a honeycomb sandwich structure 302 is bonded to the surface via structural adhesive. The honeycomb sandwich structure 302 is made of 6061-T6 aluminum alloy through extrusion, featuring a regular hexagonal honeycomb core with an inscribed circle diameter of 10mm-25mm per cell and an overall thickness of 30mm-60mm. Both its inner and outer surfaces are coated with a high-reflectivity layer to form a reflective layer. The function of the honeycomb sandwich structure 302 is to provide extremely high specific strength to withstand vehicle loads, while its large internal surface area constitutes an efficient heat dissipation channel and reflects internal light to the surface of the photovoltaic power generation unit 1 to improve power generation efficiency.

[0026] Among them, the most common crystalline silicon photovoltaic cells, such as monocrystalline silicon and polycrystalline silicon, are most sensitive to visible to near-infrared light, and their spectral response peaks are usually between 500nm and 900nm. They exhibit very high photoelectric conversion efficiency in the visible light band (500nm to 700nm, green to red light range). Therefore, the flexible LED panel uses an emission spectral peak of 550nm. At the bottom of the honeycomb sandwich structure 302, a monocrystalline silicon photovoltaic power generation unit 1 is fixedly installed using thermally conductive adhesive. On the inner walls of both sides of the honeycomb sandwich structure 302, a flexible LED panel is attached as a lighting component 5. The function of the lighting component 5 is to provide road lighting or display dynamic traffic signs at night or under low light conditions. Its spectral design facilitates recycling by the photovoltaic power generation unit 1. That is, when the lighting light does not irradiate the scattering state of the electronically controlled dimming film 4, it does not serve as lighting; therefore, the photovoltaic power generation unit 1 will recycle a portion of the light irradiated onto its surface to generate electricity, with an estimated recovery rate of 0.3-5%.

[0027] Among them, such as Figure 6 As shown, a sealed heat dissipation plate 303 is connected to the bottom of the honeycomb sandwich structure 302 via brazing. The sealed heat dissipation plate 303 is die-cast from a polycarbonate composite material filled with 30% by volume boron nitride ceramic powder, and has a thickness of 20mm. A 1mm thick thermally conductive silicone pad 3031 is placed between the bottom surface of the photovoltaic power generation unit 1 and the top surface of the sealed heat dissipation plate 303. An aluminum thermally conductive sheet 3032 is embedded in the sealed heat dissipation plate 303 using an insert injection molding process. The sealed heat dissipation plate 303, the silicone pad 3031, and the aluminum thermally conductive sheet 3032 together constitute a high-efficiency heat dissipation and bottom sealing subsystem, the function of which is to efficiently conduct and dissipate the heat generated by the photovoltaic power generation unit 1 and the lighting component 5, while ensuring that the bottom of the component is sealed and waterproof.

[0028] Among them, such as Figure 6 As shown, a single load-bearing heat dissipation module plate 3 is fixedly installed on the leveled roadbed 2 using anchor bolts. On one of the front and rear sides of the load-bearing heat dissipation module plate 3, a male tenon 304 is machined, and on the other side, a matching female mortise 305 is machined. On the upper edges of the left and right sides of the load-bearing heat dissipation module plate 3, slots are provided, and the installation is secured by vertically sliding locking pins. Inside the male tenon 304 and female mortise 305, the male and female ends of a blind-mating electrical connector are integrated. This connector integrates a 48V DC power bus and a CAN bus data communication interface. The function of the male tenon 304 and female mortise 305 is to achieve rapid and precise mechanical splicing between modules and automated electrical and data communication.

[0029] Each photovoltaic road module includes a battery pack and a main controller. The electrical energy generated by the photovoltaic power generation unit 1 is stored in the battery pack after being managed by the charging controller. The battery pack supplies power to the lighting components 5, the electronically controlled dimming film 4, and various sensors via a power bus. Each heat dissipation module 3 integrates a microprocessor, which is connected to a temperature sensor to monitor internal temperature, a light intensity sensor to monitor ambient light, and a pressure sensor installed between the microprocessor and the roadbed 2. All microprocessors are connected to the main controller installed in the road section via a data communication bus. The main controller, sensors, and microprocessors constitute a distributed intelligent control system. For example, when the light intensity sensor detects that the ambient illuminance is below a set value and the pressure sensor detects a vehicle passing by, the main controller can instruct the electronically controlled dimming film 4 of the module in that area to switch to a diffused state and illuminate the lighting components 5, achieving on-demand lighting.

[0030] Operating Process: During the day when there is sufficient sunlight, the main controller controls the electrically controlled dimming film 4 to be in a transparent state. Sunlight penetrates the supporting panel 301 and the electrically controlled dimming film 4, and after being optimized by the microprism array, it shines onto the photovoltaic power generation unit 1 to generate electricity. At night or in tunnels, the main controller controls the electrically controlled dimming film 4 to switch to a scattering state and activates the lighting component 5. The light is scattered by the electrically controlled dimming film 4 to form a uniform and soft surface light source, providing road lighting. When arrows or signs need to be displayed, this can be achieved by controlling the flexible LED panels of the lighting component 5 in zones.

[0031] The above-disclosed embodiments are merely a few specific examples of the present invention. However, the embodiments of the present invention are not limited thereto, and any variations that can be conceived by those skilled in the art should fall within the protection scope of the present invention.

Claims

1. A modular integrated photovoltaic road component, comprising a photovoltaic power generation unit (1) and a roadbed (2); characterized in that, It also includes a heat dissipation module board (3) and an electronically controlled dimming film (4); The load-bearing heat dissipation module plate (3) includes a load-bearing panel (301), a honeycomb sandwich structure (302), and a sealed heat dissipation plate (303); the top and bottom of the honeycomb sandwich structure (302) are respectively connected to the load-bearing panel (301) and the sealed heat dissipation plate (303). A photovoltaic power generation unit (1) is fixedly installed inside the honeycomb sandwich structure (302); the bottom surface of the load-bearing heat dissipation module plate (3) is fixedly installed to the top surface of the roadbed (2); An electrically controlled dimming film (4) is provided inside the carrier panel (301); a lighting component (5) is provided between the photovoltaic power generation unit (1) and the carrier panel (301); Modular splicing is performed between the sides of each pair of adjacent heat dissipation module plates (3).

2. The modular integrated photovoltaic road module as described in claim 1, characterized in that, The support panel (301) is made of polycarbonate material, and the top surface of the support panel (301) is coated with an ultra-wear-resistant self-cleaning layer; the ultra-wear-resistant self-cleaning layer is a transparent microcrystalline ceramic coating prepared by sol-gel method, and its surface Mohs hardness is ≥8; the ultra-wear-resistant self-cleaning layer is bonded to the electronically controlled dimming film (4) through a polyurethane elastomer film, and the electronically controlled dimming film (4) is located below the ultra-wear-resistant self-cleaning layer.

3. A modular integrated photovoltaic road module as described in claim 2, comprising a microprism array, wherein the microprism array includes a microlens structure and an optical waveguide structure; characterized in that, The lower surface of the bearing panel (301) is precisely imprinted with a micro prism array according to the road orientation and latitude and longitude information of the road section. The micro prism array is located below the electronically controlled dimming film (4). The micro prism array is used to refract the low-angle incident sunlight so that it is directed more vertically towards the photovoltaic power generation unit (1) below.

4. A modular integrated photovoltaic road module as described in claim 3, characterized in that, The electrochromic film (4) is a polymer-dispersed liquid crystal film or a solid electrochromic film; When no voltage is applied to the electronically controlled dimming film (4), the electronically controlled dimming film (4) is in a scattering state and enters the scattering illumination mode; When a specific voltage is applied to the electronically controlled dimming film (4), the electronically controlled dimming film (4) quickly switches to a transparent state and enters the light-transmitting power generation mode.

5. A modular integrated photovoltaic road module as described in claim 1, characterized in that, The honeycomb sandwich structure (302) is made of aluminum alloy manufactured by extrusion molding process, and its interior is a regular hexagonal honeycomb core structure; the surface of the honeycomb sandwich structure (302) is provided with a reflective layer.

6. A modular integrated photovoltaic road module as described in claim 1, characterized in that, A silicone gasket (3031) is fixed between the top surface of the sealed heat sink (303) and the bottom surface of the photovoltaic power generation unit (1); the sealed heat sink (303) is made of polycarbonate material and is filled with ceramic powder; a heat-conducting sheet (3032) is provided below the silicone gasket (3031) on the sealed heat sink (303).

7. A modular integrated photovoltaic road module as described in claim 1, characterized in that, The lighting component (5) uses a flexible LED panel with an emission spectrum of 500nm to 700nm, and each of the flexible LED panels is fixedly connected to the inner wall of the honeycomb sandwich structure (302).

8. A modular integrated photovoltaic road module as described in claim 1, characterized in that, The load-bearing heat dissipation module (3) adopts a stacked rectangular module structure; a male tenon (304) and a female mortise (305) are respectively provided between the sides of each two adjacent load-bearing heat dissipation module (3); each two adjacent load-bearing heat dissipation module (3) are modularly spliced ​​together by the male tenon (304) and the female mortise (305).

9. A modular integrated photovoltaic road module as described in claim 8, comprising a battery pack; characterized in that, The photovoltaic power generation unit (1) charges the battery pack through a charging controller; the male tenon (304) and female tenon (305) are respectively provided with the male and female ends of the blind-fit electrical connector; the blind-fit electrical connector includes a power bus and a data communication bus, the battery pack wires are connected to the power bus, the battery pack supplies power to each component through the power bus, and the data communication bus forms a communication network for each component.

10. A modular integrated photovoltaic road module as described in claim 9, characterized in that, A temperature sensor and a light intensity sensor are fixedly installed inside the heat dissipation module (3), and a pressure sensor is fixedly installed between the heat dissipation module (3) and the roadbed (2); the temperature sensor, the light intensity sensor, and the pressure sensor are all electrically connected to a microprocessor, and the microprocessor is electrically connected to an electronically controlled dimming film (4); a master controller is fixedly installed in each section of the roadbed (2), and each microprocessor is electrically connected to a master controller through a data communication bus.

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