Frameless Solar Edge Sealing Tape for Lightweight Weather Protection
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Solution Overview
Problem
Existing solar assemblies require aluminum alloy frames for edge protection, which increase weight and cost, and have complex mounting operations, making them unsuitable for applications like photovoltaic curtain walls and roof installations.
Innovation Solution
A frameless adhesive tape with an adhering layer, optional adhesive layers, and an aging-resistant protective layer is used to seal the edges of solar assemblies, reducing weight, simplifying installation, and lowering manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If aluminum alloy frames are used to seal and protect solar assembly edges, then edge protection and sealing are achieved, but weight increases and manufacturing cost increases
Solution Approach 1:
The patent changes the material parameter from metal (aluminum alloy) to polymer (adhesive tape), fundamentally altering the weight characteristic while maintaining the protective function. The adhesive tape provides edge sealing and protection with significantly reduced weight compared to aluminum frames.
Solution Approach 2:
The adhesive tape is positioned as a lighter, more economical alternative to aluminum frames. While aluminum frames provide durable long-term protection, the adhesive tape offers a cost-effective solution that achieves sufficient protection for many applications without the high weight and cost of metal frames.
2Reliability
If aluminum alloy frames are used to seal and protect solar assembly edges, then edge protection is achieved, but manufacturing cost increases
Solution Approach 1:
The adhesive tape is presented as a lower-cost alternative to aluminum framing systems. The tape eliminates the need for expensive metal materials, specialized framing components, and complex assembly hardware, thereby reducing overall manufacturing cost while maintaining adequate edge protection.
Solution Approach 2:
The patent changes the material parameter from metal to polymer, which fundamentally alters the cost structure. Polymer adhesive tapes are generally less expensive than aluminum framing systems, including both material costs and associated installation costs.
3Strength
If aluminum alloy frames are used for edge sealing, then structural support is provided, but mounting operation complexity increases
Solution Approach 1:
The patent extracts the edge sealing and protective function from the complex aluminum framing system, isolating it into a simple adhesive tape application. This separates the essential protective function from the unnecessary structural complexity of metal frames.
Solution Approach 2:
The patent changes the material parameter from rigid metal to flexible polymer, which fundamentally alters the installation characteristics. The adhesive tape can be easily applied to irregular surfaces and requires no specialized mounting tools or complex assembly procedures.
4Weight of moving object
If adhesive tape is used to seal edges instead of frames, then weight is reduced, but weather resistance and durability may be compromised
Solution Approach 1:
The adhesive tape is designed as a multi-layer composite structure combining different materials to achieve both light weight and superior weather resistance. The composite construction integrates the adhesive properties of pressure-sensitive adhesives with the protective properties of polymer films, creating a material that is both lightweight and durable.
Solution Approach 2:
The patent changes the material parameter from metal to advanced polymer composites, which alters both weight and durability characteristics. The polymer composite maintains adequate structural support while providing excellent resistance to UV radiation, moisture, and temperature cycling.
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 adhesive tape effectively seals solar assembly edges, providing superior weather resistance, abrasion resistance, and cushioning, while reducing production time and costs, and maintaining assembly integrity under various environmental conditions.
Implementation Method 1
an adhering layer for adhesion and cushioning, which is used to contact the edge of an article
Implementation Method 2
an aging-resistant protective layer on the adhering layer, which comprises: an optional primer layer, which is situated on the adhering layer; and a film layer, which is situated on the primer layer
Data Source
AI summary
The invention provides a frameless photo-energy assembly including a photo-energy converter, wherein an edge of the photo-energy converter is sealed by an adhesive tape, comprising an adhering layer for adhesion and cushioning; and an aging-resistant protective layer. The adhering layer is used to contact the edge of an article and comprises: a substrate layer; optionally, a first adhesive layer and a second adhesive layer situated at both sides of the substrate layer oppositely, wherein the first adhesive layer being used to be contact with the article. The aging-resistant protective layer is situated on the adhering layer, which comprises: an optional primer layer, which is situated on the adhering layer; and a film layer, which is situated on either the primer layer or the substrate or the second adhesive layer. The invention further provides an adhesive tape for sealing an edge of an article and an article made of the assembly.