Epoxy Clear Fiber Composite Solar Panel Cover Plate
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Solution Overview
Problem
Conventional glass cover plates in solar panels are heavy, prone to shattering under impact, and lack the necessary optical clarity and light transmittance, posing risks and inefficiencies in energy conversion.
Innovation Solution
An epoxy-based clear fiber composite with a refractive index matching that of glass fibers, utilizing cycloaliphatic epoxy resins and anhydride curing agents, providing high optical clarity, mechanical strength, and impact resistance, potentially replacing traditional glass cover plates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If glass cover plates are used in solar panels, then protection and structural integrity are provided, but weight increases and impact resistance deteriorates
Solution Approach 1:
The patent changes the material parameters by using epoxy resin with specifically controlled refractive index (1.520-1.565) and low aromatic content (60 wt% or higher non-aromatic components) to achieve both light transmittance and mechanical strength. The resin composition parameters (viscosity 100-1000 cPs at 25°C, pot life 6+ hours at 25°C) are optimized to balance processing ease with final material performance, resolving the contradiction between protection and weight.
Solution Approach 2:
The patent creates a composite material system consisting of epoxy resin matrix combined with glass fiber reinforcement. This composite structure provides the mechanical strength and impact resistance of glass fibers while the epoxy resin matrix keeps the overall weight lower than solid glass, simultaneously achieving both protection and weight reduction.
2Illumination intensity
If glass cover plates are used in solar panels, then structural protection is provided, but optical clarity and light transmittance deteriorate
Solution Approach 1:
The patent precisely controls the refractive index of the epoxy resin (1.520-1.565) to match that of glass fibers, minimizing optical contrast and maximizing light transmittance. The chemical composition is optimized with 60 wt% or higher non-aromatic components to reduce UV absorption and maintain optical clarity, directly resolving the contradiction between protection and optical performance.
3Reliability
If glass cover plates are used in solar panels, then protection is provided, but shattering risk increases under excess force
Solution Approach 1:
The patent changes from brittle glass material to ductile epoxy resin material, fundamentally altering the failure mode from catastrophic shattering to gradual deformation. The resin's toughness and flexibility provide progressive damage tolerance, absorbing impact energy without sudden failure, thereby eliminating shattering risk while maintaining protection.
Solution Approach 2:
The glass fiber-reinforced epoxy composite combines the high strength of glass fibers with the toughness of epoxy resin. The fiber reinforcement provides structural integrity and protection, while the resin matrix prevents catastrophic failure by distributing stress and preventing crack propagation, resolving the shattering risk contradiction.
4Reliability
If glass cover plates are used in solar panels, then protection is provided, but vehicle installation safety deteriorates
Solution Approach 1:
The patent transitions from brittle glass to ductile epoxy resin, changing the material's response to impact from shattering to deforming. This parameter change eliminates the generation of hazardous debris while maintaining protective function, directly addressing vehicle installation safety concerns.
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 epoxy-based clear fiber composite offers a lightweight, impact-resistant, and optically clear solution for solar panel cover plates, enhancing light transmittance and mechanical properties while maintaining the structural integrity and optical stability required for solar panels.
Implementation Method 1
The epoxy-based clear fiber composite may have a refractive index ranging from 1.520 to 1.530 or 1.550 to 1.565, and a difference between the refractive index of the fiber reinforcement and a refractive index of the cured matrix resin of 0.001 or less
Data Source
AI summary
An epoxy-based resin composition for clear fiber composites includes epoxy resins and an anhydride curing agent. The epoxy resins include at least one epoxy resin having a refractive index higher than a refractive index of glass fibers, and at least one cycloaliphatic epoxy resin. The amount of non-aromatic components in the epoxy-based resin composition is 60 wt % or higher, based on the total amount of the epoxy resins and the anhydride curing agent. An epoxy-based clear fiber composite for a cover plate in a solar cell panel includes a cured matrix resin and a fiber reinforcement. The epoxy-based clear fiber composite has a refractive index ranging from 1.520 to 1.530 or 1.550 to 1.565, while the difference between the refractive index of the fiber reinforcement and the cured matrix resin is 0.001 or less. A multi-layer epoxy-based clear fiber composite includes a plurality of the epoxy-based clear fiber composite.