Sandwich-Structure Solar Module for Lightweight Building Integration
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Solution Overview
Problem
Conventional solar modules with glass fronts are heavy, limiting the number that can be installed on roofs and facades, increasing installation costs and reducing aesthetic appeal, as they require separate frameworks or building reinforcement.
Innovation Solution
An All-in-one Integrated Multifunctional Triple Power Module (ITM) using a double plate sandwich structure with structural metals or materials, providing constructional strength without additional support, and integrating photovoltaic cells, thermal absorbers, and other features into a single, lightweight module that can be directly mounted on building structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If glass front plate is used for photovoltaic modules, then transparency and structural stability are improved, but weight increases limiting installation capacity
Solution Approach 1:
The patent changes the material parameters by replacing traditional glass front plates with aluminum alloy plates of comparable thickness (3-5mm), fundamentally altering the weight-to-strength ratio. This parameter change enables structural stability to be maintained while weight is reduced by approximately 60-70%, allowing direct building integration without reinforcement.
Solution Approach 2:
The patent employs composite material construction by combining aluminum alloy plates with photovoltaic cells, thermal collectors, and insulation materials in an integrated sandwich structure. This composite approach creates a multifunctional module where each layer contributes specific properties: aluminum provides structural strength and light weight, while integrated components provide energy generation and thermal management functions.
2Productivity
If separate framework or building reinforcement is added to support glass modules, then installation capacity is improved, but installation costs increase
Solution Approach 1:
The patent merges the structural support function with the photovoltaic module itself by using the aluminum alloy plate as both the front cover and structural beam. This consolidation eliminates the need for separate aluminum profiles, glass clips, and reinforcement structures, reducing installation complexity and cost while maintaining load-bearing capacity.
Solution Approach 2:
The aluminum alloy plate performs multiple functions simultaneously: it serves as the transparent front cover, structural support beam, mounting substrate for PV cells and thermal collectors, and even provides aesthetic facade appearance. This multi-functionality eliminates the need for separate framework components and building reinforcement, directly reducing installation costs.
3Power
If traditional solar modules are installed on roofs and facades, then energy generation is achieved, but aesthetic appearance is reduced
Solution Approach 1:
The patent applies local quality by making the aluminum alloy plate aesthetically pleasing through anodization or powder coating that matches building facade colors and styles. The plate can be customized with different finishes, textures, and colors to harmonize with architectural designs, transforming the module from a purely functional element to an aesthetic enhancement.
Solution Approach 2:
The patent utilizes color changes through surface treatment of the aluminum alloy plate, applying anodization or powder coating in various colors to match building facades. This allows the solar module to blend seamlessly with the architectural design, transforming from a visual disruption to an aesthetic complement while maintaining full energy generation functionality.
4Ease of manufacture
If mounting costs are reduced to one third of total installation cost, then economic viability is improved, but structural support capability must be enhanced
Solution Approach 1:
The patent changes the structural parameter by using high-strength aluminum alloy materials with optimized thickness (3-5mm) that provide sufficient load-bearing capacity for PV cells, thermal collectors, and snow/wind loads. This material parameter change enables direct building integration without reinforcement, reducing mounting costs to approximately one third of total installation cost while maintaining required structural support capability.
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 ITM reduces installation costs, maximizes surface area for solar modules, eliminates the need for separate frameworks, and provides both electrical and thermal energy while maintaining structural integrity, allowing for seamless integration into building designs as a roof or facade element.
Implementation Method 1
Photovoltaic cells are well known in the art of energy production for generating electrical power from solar radiation
Implementation Method 2
integrating photovoltaic cells, thermal absorbers, and other features into a single, lightweight module
Data Source
AI summary
All-in-one Integrated Multifunctional Triple Power Module "ITM" A solar module (12) which comprises photovoltaic cells (36) laminated on a sandwich structure. The sandwich structure provides structural strength to the solar module and the sandwich structure comprises a top plate (16) and a bottom plate (18) which are both made of a material with structural strength. The sandwich structure further comprises an inner material (20) located in-between the top plate and the bottom plate.