Low profile solar panel and method of manufacture
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Solution Overview
Problem
Off-grid solar panel systems for mobile applications face challenges in reducing wind resistance and dynamic pressures, while also needing to consider size, mounting structure, and aesthetic constraints, which affect fuel efficiency and panel durability.
Innovation Solution
A solar panel assembly with an aerodynamic frame design featuring arcuate members and a mounting system that includes a T-nut and spacer assembly to secure the panels on vehicles, reducing wind resistance and enhancing attachment stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If solar panels are installed on mobile vehicles, then off-grid power generation is enabled, but wind resistance and dynamic pressures increase
Solution Approach 1:
The frame members incorporate arcuate members that form aerodynamic outer edges with curved surfaces. This curvature allows air to flow smoothly over the solar panel assembly, reducing turbulence and dynamic pressures caused by wind resistance during vehicle motion.
Solution Approach 2:
The solar panel assembly is designed with a low-profile construction that changes the geometric parameters of the panel, specifically reducing its height and overall aerodynamic drag coefficient. This parameter optimization minimizes the harmful effects of wind resistance while maintaining power generation capability.
2Object-affected harmful factors
If solar panels are designed with low-profile construction, then aerodynamic performance improves, but mounting structure complexity increases
Solution Approach 1:
The mounting system employs a nested structure where T-nuts are received within channels of the frame members, and spacers are coupled to the T-nuts. This nested arrangement secures the solar assembly while maintaining a compact, low-profile design without excessive structural complexity.
Solution Approach 2:
The mounting structure is divided into separate functional components: frame members with channels, T-nuts for attachment, spacers for positioning, and mounting feet for securing. This segmentation allows each component to perform its specific function efficiently while simplifying the overall assembly process.
3Object-affected harmful factors
If aerodynamic frame members with arcuate members are used, then wind resistance is reduced, but manufacturing complexity increases
Solution Approach 1:
The arcuate members provide standardized curved profiles that can be manufactured using consistent forming processes. These curved components are designed to be integrated into the frame structure through standardized connection methods, balancing aerodynamic performance with manufacturability.
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 reduces wind resistance, improves fuel efficiency, and enhances the durability of solar panels on mobile vehicles by providing a secure and aerodynamic mounting system that minimizes dynamic pressures and stresses.
Implementation Method 1
The solar array includes a plurality of photovoltaic cells
Implementation Method 2
Each frame member of the plurality of frame members includes an arcuate member that forms an aerodynamic outer edge of the frame member
Data Source
AI summary
A solar panel assembly includes a substrate and a solar array coupled to the substrate. The solar array includes a plurality of photovoltaic cells. An optical layer is disposed over the solar array. The optical layer, the solar array, and the substrate together form a solar assembly. A frame surrounds the solar assembly and includes a plurality of frame members. Each frame member of the plurality of frame members includes an arcuate member that forms an aerodynamic outer edge of the frame member.