Composite Automotive Panels With Embedded Photovoltaic Cells

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Solution Overview

Problem

Existing photovoltaic cell installations on vehicles are bulky, disrupt aerodynamics, compromise aesthetics, and are affected by harsh environmental conditions, leading to reduced longevity.

Innovation Solution

A structural composite panel integrating photovoltaic cells with a resin layer and structural reinforcement, including fibers like carbon or glass, encapsulated in resin, and protected by a hard coat or strengthened glass layer, ensuring durability and aesthetic integration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If photovoltaic cells are installed on vehicle rooftops, then solar energy conversion is achieved, but the panels become bulky and heavy

Engineering Contradiction:

Improvesolar energy conversionVSAvoidpanel weight

Core Design Contradiction:

Use of energy by moving objectVSWeight of moving object

Solution Approach 1:

The patent combines photovoltaic cells with structural composite panels, merging the energy conversion function with the vehicle's structural body. This integration eliminates separate mounting structures and reduces overall weight by making the panel itself load-bearing.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The use of composite materials in the structural panel allows for lightweight construction while maintaining structural integrity. The composite structure enables thin-profile photovoltaic integration without compromising strength, addressing both weight and energy conversion requirements.

Inventive Principle:

Principle #40Composite materials

2Use of energy by moving object

If traditional rooftop solar panels are used, then photovoltaic function is provided, but aerodynamics are disrupted

Engineering Contradiction:

Improvephotovoltaic functionVSAvoidaerodynamics

Core Design Contradiction:

Use of energy by moving objectVSShape

Solution Approach 1:

By integrating photovoltaic cells directly into the vehicle's body panels, the design merges aerodynamic surfaces with energy-generating surfaces. The panel contours follow the vehicle's aerodynamic lines, eliminating protruding structures that would disrupt airflow.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The photovoltaic integration is applied locally to specific body panels where aerodynamic requirements are met. The design allows different regions of the vehicle to have different levels of photovoltaic integration based on local aerodynamic and structural considerations.

Inventive Principle:

Principle #3Local quality

3Use of energy by moving object

If visible solar panels are installed, then energy conversion is achieved, but vehicle aesthetics are compromised

Engineering Contradiction:

Improveenergy conversionVSAvoidaesthetics

Core Design Contradiction:

Use of energy by moving objectVSShape

Solution Approach 1:

The patent merges photovoltaic functionality with aesthetic body panels, creating a unified design where the energy-generating surface is indistinguishable from the vehicle's exterior styling. This eliminates the visual contrast between traditional solar panels and vehicle bodywork.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The body panels serve multiple functions simultaneously: structural support, aesthetic appearance, and photovoltaic energy conversion. This multi-functionality allows the same surface to fulfill diverse requirements without compromise.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Use of energy by moving object

If photovoltaic cells are exposed to harsh environmental conditions, then solar energy generation is maintained, but cell lifespan is reduced

Engineering Contradiction:

Improveenergy generationVSAvoidcell lifespan

Core Design Contradiction:

Use of energy by moving objectVSReliability

Solution Approach 1:

The patent implements protective measures beforehand by encapsulating photovoltaic cells within layered composite structures that provide environmental buffering. These protective layers shield cells from temperature extremes, moisture, and mechanical stress before damage can occur.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

Composite material structures with encapsulation layers protect photovoltaic cells from environmental degradation. The multi-layer composite construction provides thermal insulation, moisture barrier, and mechanical protection, extending cell lifespan while maintaining energy generation capability.

Inventive Principle:

Principle #40Composite materials

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

The solution provides lightweight, aesthetically pleasing, and durable photovoltaic solutions for vehicles, protecting cells from environmental factors and extending their lifespan while ensuring consistent energy production.

Implementation Method 1

Photovoltaic cells, commonly known as solar cells, are widely used to convert sunlight into electrical energy

Methodology Applied

Scientific EffectPhotovoltaic effect: Photovoltaic Effect

Implementation Method 2

The structural reinforcement is commingled with a non-structural 3d stitch to consolidate the fiber and preform

Methodology Applied

Scientific EffectEncapsulation:

Implementation Method 3

a protective layer disposed on the resin layer

Methodology Applied

Scientific EffectPhysical protection:

Data Source

PatentUS20260033016A1Photovoltaic cells in structural composite automotive panels

Publication Date: 2026.01.29 GM GLOBAL TECHNOLOGY OPERATIONS LLC

AI summary

A structural composite panel is provided. The structural composite panel includes a first layer, at least one photovoltaic cell disposed on the first layer, a resin layer including the resin, and a protective layer disposed on the resin layer. The first layer includes a resin and structural reinforcement. A portion of the first layer includes the structural reinforcement encapsulated in the resin, and a portion of the first layer includes no structural reinforcement. The resin layer is disposed on the at least one photovoltaic cell.