Integrated Solar Car Panels with Edgeless Encapsulation
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Solution Overview
Problem
Current solar cars have separate solar cells that are affixed to the vehicle after manufacturing, which can lead to inefficiencies in energy harvesting and integration with the car's design, as well as potential protection issues for the solar cells.
Innovation Solution
Integration of solar cells into the vehicle's panels, such as the roof, hood, trunk lid, and doors, using photovoltaic materials like perovskite, CIGS, or gallium arsenide, encapsulated with layers for protection and efficiency, and connected to a control system for optimal energy conversion and storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If solar cells are manufactured separately and affixed to the car after manufacturing, then the car can be produced using conventional manufacturing processes, but the energy harvesting efficiency and integration with the car's design are reduced
Solution Approach 1:
The patent combines the solar cell manufacturing process with the car panel manufacturing process into a single integrated production line. Solar cells are manufactured directly within the mold cavity during panel formation, eliminating separate affixing steps and achieving both conventional manufacturing ease and high energy harvesting efficiency through seamless integration
Solution Approach 2:
The car panel serves multiple functions simultaneously: it provides structural support, aesthetic appearance, and integrated solar energy harvesting. The panel includes both the solar cell layer and protective encapsulant as unified components, making the panel itself a multi-functional element that combines structural and energy-generating roles
2Ease of operation
If solar cells are separately affixed to the car, then installation is simplified, but the solar cells lack protection and integration with the vehicle structure
Solution Approach 1:
The solar cell is nested within the encapsulant layer during mold manufacturing, with the solar cell positioned inside the cavity and the encapsulant formed around it. This nested structure provides inherent protection and integration, eliminating the need for separate installation steps while ensuring the solar cell is securely enclosed and protected within the panel structure
Solution Approach 2:
The solar cell is pre-positioned and protected within the encapsulant during the panel manufacturing process itself, before the car assembly begins. This preliminary integration ensures the solar cell is already protected and securely integrated into the vehicle structure, eliminating subsequent installation steps and ensuring reliability from the outset
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
Enhances energy harvesting efficiency, provides a durable and long-lasting solar cell integration that is integrated into the vehicle's structure, improving the overall performance and longevity of the solar car's energy generation capabilities.
Implementation Method 1
Solar cars include solar cells to harvest energy from the sun and use the harvested energy to power an electric motor
Data Source
AI summary
Described herein are apparatuses, systems, and methods for a solar car. The exterior of the solar car is comprised of smoothly curved and continuous photovoltaic cells. The exterior car parts, e.g., roof, doors, hood, trunk and so forth, may include integrated photovoltaic cells, all manufactured in the shape of the corresponding car parts. The photovoltaic cells are meta-encapsulated in an edgeless manner, and may utilize superconducting anodes. A first encapsulate may be polychlorotrifluoroethylene, an extreme water barrier. A second encapsulate, e.g., silicone, may be a water barrier and shock absorber. A third encapsulate may be UV stabilized polycarbonate or low iron glass. A street legal solar car may be constructed upon an electric car chassis. A competition solar car has one or more hyper-efficient electric motors, that may utilize superconducting wire in their armatures. Superconducting wire may also be used in the vehicle chassis.