Corrugated Solar Panel Edges for Watertight Nested Mounting
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Solution Overview
Problem
Existing solar panels are cumbersome and difficult to install, requiring heavyweight materials that cannot be efficiently mounted on structures that cannot support traditional glass-covered panels, and there is a need for improved installation and removal methods that ensure water-tight sealing.
Innovation Solution
The development of corrugated solar panels with a flexible, rollable, and foldable central region and corrugated edges that allow for efficient installation, water-tight mounting, and rapid removal or replacement, utilizing thermoforming processes to create faceted regions for mechanical support and electrical connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional glass-covered solar panels are used, then structural integrity and electrical functionality are maintained, but weight increases and installation becomes difficult
Solution Approach 1:
The solar panel is divided into a central photovoltaic region and separate corrugated non-planar regions attached to the edges. This segmentation allows the panel to use lighter materials in the central region while maintaining structural integrity through the attached corrugated regions, resolving the contradiction between weight reduction and strength maintenance.
Solution Approach 2:
The patent employs flexible substrates and thin-film photovoltaic materials in the central region, replacing traditional heavy glass covers. These flexible components maintain sufficient structural integrity for installation and operation while dramatically reducing the overall weight of the solar panel.
2Ease of operation
If flexible and lightweight materials are used for solar panels, then ease of installation improves, but water-tight sealing becomes difficult
Solution Approach 1:
The corrugated non-planar regions feature curved, wave-like structures that naturally interlock with adjacent panels. This curvature design creates overlapping edges that form water-tight seals while maintaining the flexibility and lightweight characteristics of the panel, resolving the contradiction between ease of installation and sealing reliability.
Solution Approach 2:
The corrugated regions of adjacent solar panels are designed to nest within each other, creating an interlocking configuration. This nesting arrangement ensures water-tight sealing between panels while keeping the overall structure lightweight and easy to install, as the sealing function is integrated into the panel edges rather than requiring separate heavy sealing components.
3Strength
If corrugated regions are added for mechanical support, then structural integrity improves, but device complexity increases
Solution Approach 1:
The corrugated non-planar regions serve multiple functions simultaneously: they provide mechanical support and structural integrity, enable water-tight sealing through interlocking edges, and facilitate electrical connectivity between adjacent panels. This multi-functionality reduces overall device complexity by consolidating multiple structural requirements into a single integrated component rather than requiring separate elements for each function.
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
Enables rapid and efficient installation, water-tight sealing, and easy removal of solar panels, reducing the need for heavy mechanical fasteners and providing structural integrity while maintaining electrical functionality.
Implementation Method 1
a central photovoltaic region, including one or more photovoltaic cells that are configured to convert light to electricity
Data Source
AI summary
Corrugated solar panels for improved installation and water-tight mounting. A solar panel includes: a central photovoltaic region, including one or more photovoltaic cells that are configured to convert light to electricity; and at least one corrugated non-planar region, that is attached to the central photovoltaic region, and that is configured to overlap a complementing corrugated non-planar region of another solar panel, and to enable nested mechanical attachment of that solar panel to the other solar panel. Optionally, the corrugated non-planar region is non-photovoltaic. Optionally, the corrugated non-planar region is photovoltaic. Optionally, the corrugated non-planar region is detachably attached to the central photovoltaic region. Optionally, the corrugated non-planar region is non-detachably attached to the central photovoltaic region.