Composite Insulated Panel With Integrated PV Module Insulation
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Solution Overview
Problem
There is a need for a thermally efficient system for building cladding that incorporates photovoltaic solar collectors effectively, as existing solutions do not maximize energy efficiency and require additional on-site assembly and safety measures.
Innovation Solution
A composite insulated panel is manufactured by cutting a hole in a first sheet to accommodate a photovoltaic solar collector module, sealing it, and inserting a second sheet with a connector housing, while injecting insulating material between the sheets and the solar collector module, which includes profiling the edges for efficient solar exposure and easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If photovoltaic elements are bonded to panel using cold bonding adhesive, then photovoltaic material can be integrated, but thermal efficiency is reduced and additional on-site assembly is required
Solution Approach 1:
The photovoltaic module is pre-integrated into the insulating panel during manufacturing by forming a recess in the insulating material, placing the module within it, and sealing with adhesive before the panel is installed. This preliminary integration eliminates the need for separate on-site assembly and ensures optimal thermal contact between the module and insulating material, thereby maintaining thermal efficiency while achieving photovoltaic integration.
2Ease of manufacture
If photovoltaic panels are integrated during manufacturing, then on-site assembly costs and safety risks are reduced, but manufacturing complexity increases
Solution Approach 1:
The panel is divided into functional zones: an insulating material body, a recess formed within it, a photovoltaic module placed in the recess, and sealing adhesive applied around the module. This segmentation allows each component to be prepared and assembled in a controlled manufacturing environment, simplifying the integration process despite the added complexity of multiple steps.
Solution Approach 2:
Adhesive serves as an intermediary material that seals the photovoltaic module to the insulating panel and fills gaps between components. This intermediary substance ensures thermal contact and structural integrity, facilitating the integration of the module during manufacturing while managing the complexity of the assembly process.
3Reliability
If photovoltaic module is sealed to first sheet with adhesive, then module is secured in position, but additional materials and steps are required
Solution Approach 1:
The adhesive serves dual functions: it seals the photovoltaic module to the insulating panel to secure the module in position, and it fills the gaps between the module and the insulating material to ensure thermal contact. By combining these two functions into a single material application step, the need for separate sealing and thermal contact materials is eliminated, reducing overall complexity while maintaining reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enhances solar energy collection efficiency, reduces on-site assembly costs and safety risks, and minimizes material and labor costs by integrating electrical connections and photovoltaic panels during manufacturing, ensuring a robust and efficient solar energy harvesting system.
Implementation Method 1
a body of insulating material between inner face of the second sheet, inner face of the first sheet and inner face of the photovoltaic solar collector module
Implementation Method 2
photovoltaic solar collector module
Data Source
AI summary
A method for manufacturing a composite insulated panel (1) comprising the steps of: providing a first sheet (2); cutting a hole (7) in the first sheet (2) to accommodate a photovoltaic solar collector module (8); inserting the solar collector module (8) into the cut-out hole; sealing the solar collector module to the first sheet (2); providing a second sheet (3), the second sheet having an opening therein to receive a connector housing (22); leading electrical connections from the solar collector module through the connector housing; and providing a body (4) of insulating material between the inner face of the second sheet and the inner face of the first sheet and the inner face of the photovoltaic solar collector module.