Solar Battery Module Resin Panel Edge Rigidity
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Solution Overview
Problem
Conventional on-board solar battery modules face challenges in reducing weight while maintaining predetermined flexural rigidity, particularly when using resin panels instead of inorganic glass, and require complex structures and increased part numbers due to the need for additional support members.
Innovation Solution
The design incorporates a resin panel top surface layer with a thicker peripheral edge portion for enhanced flexural rigidity, a back surface layer with matching resin material for reduced linear expansion differences, and a raised portion to control buckling, allowing for a simpler structure and reduced weight by securing the peripheral edge portion directly to the vehicle body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If inorganic glass substrate is used for top surface layer, then flexural rigidity is ensured, but weight increases
Solution Approach 1:
The top surface layer is designed with non-uniform thickness, featuring a thicker peripheral edge portion and a thinner general portion. This local quality variation provides enhanced flexural rigidity at the edges where it is most needed for structural support, while reducing weight in the central area where full thickness is not required.
Solution Approach 2:
The patent employs composite material construction by combining resin panel with aluminum alloy frames or ribs integrated into the peripheral edge portion. This composite structure achieves the desired flexural rigidity through the high-strength aluminum components while maintaining overall weight reduction compared to solid inorganic glass substrates.
2Ease of manufacture
If back surface layer is secured to vehicle skeleton members, then attachment is achieved, but detachment load acts on top surface layer
Solution Approach 1:
Instead of securing the back surface layer to vehicle skeleton members as in conventional designs, this patent inverts the approach by securing the top surface layer (specifically its peripheral edge portion) directly to the vehicle skeleton members. This reversal eliminates the detachment load issue on the top surface layer while maintaining secure attachment.
3Strength
If top surface layer thickness is increased to ensure flexural rigidity, then buckling is prevented, but weight increases
Solution Approach 1:
The top surface layer implements local quality by having different thickness regions: a thicker peripheral edge portion for structural support and buckling prevention, and a thinner general portion for weight reduction. This localized thickness variation ensures flexural rigidity only where structurally necessary.
Solution Approach 2:
The top surface layer is segmented into functionally distinct regions with different thickness characteristics. The peripheral edge portion is separated as a structurally critical zone requiring greater thickness, while the general portion is reduced in thickness, creating a segmented thickness profile that optimizes both strength and weight.
Data Source
AI summary
An on-board solar battery module includes: an encapsulant layer of power generating elements; a top surface layer joined to the encapsulant layer on the side corresponding to a light receiving surface side of the power generating elements; and a back surface layer joined to the encapsulant layer on the side opposite the side corresponding to the light receiving surface side of the power generating elements. Furthermore, an end portion of the back surface layer is positioned on the inner side of an end portion of the top surface layer in an extension direction of the top surface layer, and the top surface layer has a general portion that covers the power generating elements, and a peripheral edge portion that is formed at an end portion side thereof on the outer side of the general portion, and that has a thicker panel thickness than that of the general portion.