Sandwich-Structure Solar Module to Reduce Weight and Installation Cost

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Solution Overview

Problem

Conventional solar modules with glass fronts are heavy, limiting the number that can be installed on buildings and increasing installation costs, as they require reinforcement or separate frameworks, which also detract from the aesthetic appearance.

Innovation Solution

A double plate sandwich (DPS) solar module design using structural metals or composite materials with a sinusoidal or trapezoidal corrugated inner structure, allowing for a lightweight yet strong module that can be mounted directly on building load-bearing structures without additional frameworks, incorporating photovoltaic cells and thermal absorbers for dual energy generation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If glass front plates are used in solar modules, then transparency and structural stability are improved, but weight increases significantly

Engineering Contradiction:

Improvestructural stabilityVSAvoidmodule weight

Core Design Contradiction:

StrengthVSWeight of stationary object

Solution Approach 1:

The patent changes the material parameter from glass to aluminum alloy, maintaining structural stability while significantly reducing weight. The aluminum alloy front plate provides sufficient mechanical strength without the excessive weight of glass, directly resolving the contradiction between structural stability and weight reduction.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite material construction with aluminum alloy as the base material and incorporates reinforcement structures. This composite approach achieves both lightweight properties and structural stability, eliminating the need for heavy glass while maintaining mechanical integrity.

Inventive Principle:

Principle #40Composite materials

2Productivity

If heavy solar modules are installed on buildings, then more modules can be placed on rooftops and facades, but installation costs increase due to reinforcement requirements

Engineering Contradiction:

Improveinstallation efficiencyVSAvoidinstallation complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates the heavy glass component from the module structure, replacing it with lightweight aluminum alloy. This removal of excessive weight eliminates the need for building reinforcement and complex mounting systems, directly reducing installation complexity and improving installation efficiency.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The lightweight aluminum alloy modules are designed to be self-supporting with integrated mounting features, eliminating the need for separate reinforcement structures and complex installation procedures. The modules serve their own structural needs without requiring additional heavy infrastructure.

Inventive Principle:

Principle #25Self-service

3Strength

If separate frameworks are used to support solar modules, then structural capability is improved, but aesthetic appearance deteriorates

Engineering Contradiction:

Improvestructural capabilityVSAvoidaesthetic appearance

Core Design Contradiction:

StrengthVSShape

Solution Approach 1:

The patent merges the structural support function directly into the aluminum alloy front plate itself, eliminating the need for separate external frameworks. The front plate integrates both aesthetic and structural roles, providing clean lines and uniform appearance while maintaining structural capability through the aluminum alloy material properties and design.

Inventive Principle:

Principle #5Merging (Combining)

4Ease of manufacture

If mounting costs are reduced, then total installation costs decrease, but structural support capability may be compromised

Engineering Contradiction:

Improveinstallation costVSAvoidstructural support capability

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent changes the weight parameter of the front plate material from heavy glass to lightweight aluminum alloy, which directly reduces mounting costs by eliminating reinforcement requirements while maintaining structural support capability through the inherent strength-to-weight ratio of aluminum alloy and optimized design.

Inventive Principle:

Principle #35Parameter changes

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 DPS module reduces installation costs, maximizes surface area for solar installations, and integrates electrical and thermal energy generation while maintaining a lightweight, aesthetically pleasing design, eliminating the need for separate roof or facade panels.

Implementation Method 1

Photovoltaic cells are well known in the art of energy production for generating electrical power from solar radiation

Methodology Applied

Scientific EffectPhotovoltaic effect: Photovoltaic Effect

Implementation Method 2

Solar assemblies that combine photovoltaic panels and solar thermal collectors

Methodology Applied

Scientific EffectSolar thermal absorption: Absorption (EM radiation)

Data Source

PatentUS11619423B2All-in-one integrated multifunctional triple power module

Publication Date: 2023.04.04 SAPHIRE SOLAR TECH

AI summary

A solar module includes a plurality of photovoltaic cells and a sandwich structure on which the plurality of photovoltaic cells is structurally supported. The sandwich structure includes top and bottom structural plates and an open-cell inner material located between the top and bottom structural plates.