Viscoelastic Damper Junction Box for Curved Solar Panel NVH Isolation
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Solution Overview
Problem
Curved, laminated solar panels face challenges in withstanding environmental and use conditions such as vibrations, leading to potential failure modes, and require effective mechanical and electrical coupling to vehicle structures while minimizing noise, vibration, and harshness (NVH) and reducing weight and profile.
Innovation Solution
A damper system with viscoelastic materials is used to mechanically and electrically couple solar panels to vehicle frames, providing strain relief and acting as a vibration barrier, while maintaining a low profile and reducing intrusion into the vehicle interior.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If curved, laminated solar panels are used to conform to vehicle structures, then the solar panels can be integrated into complex geometries, but they become susceptible to vibrations and environmental conditions leading to potential failure modes
Solution Approach 1:
The patent applies beforehand cushioning by incorporating a damper system with viscoelastic material between the solar panel and vehicle frame before the panel is subjected to vibrations and environmental conditions. This pre-installed damping layer absorbs and dissipates vibrational energy, protecting the solar panel from potential failure modes caused by vibrations during operation.
2Strength
If the solar panel is mechanically coupled to the vehicle frame, then structural support is provided, but stress and vibrations are transmitted to the panel
Solution Approach 1:
The patent employs an intermediary approach by introducing a damper system with viscoelastic material as a mediator between the solar panel and vehicle frame. This intermediary layer provides the necessary mechanical coupling and structural support while simultaneously isolating the solar panel from harmful vibrations and stress transmissions through its damping properties.
3Reliability
If a junction box is added for electrical coupling, then electrical connections are established, but the vehicle profile is increased and interior space is intruded
Solution Approach 1:
The patent applies merging by integrating the junction box functionality into the existing damper system structure. The viscoelastic damper material serves dual purposes: providing vibration damping and housing the electrical connections. This consolidation eliminates the need for a separate, space-consuming junction box while maintaining reliable electrical coupling between the solar panel and vehicle systems.
4Reliability
If strain relief is provided for wires and solder joints, then assembly stresses are accommodated, but the device complexity increases
Solution Approach 1:
The patent applies universality by designing the damper system to perform multiple functions simultaneously: vibration damping, mechanical coupling, electrical connection housing, and strain relief. The viscoelastic material's inherent flexibility and the damper's structural design provide strain relief for wires and solder joints as an integrated feature rather than a separate complexity-adding component.
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 damper system effectively reduces stress on solar cells, mitigates NVH, and ensures reliable electrical connections under harsh conditions, enabling the mass production of solar-enabled body panels with improved longevity and performance.
Implementation Method 1
A damper system with viscoelastic materials is used to mechanically and electrically couple solar panels to vehicle frames, providing strain relief and acting as a vibration barrier
Implementation Method 2
The damper system effectively reduces stress on solar cells, mitigates NVH, and ensures reliable electrical connections under harsh conditions
Data Source
AI summary
A solar module for industrial applications is disclosed that includes a solar panel coupled to a damper. The damper provides support against static and dynamic loads with reduced risk of damage to the solar cells in applications such as architectural, marine, aeronautical, terrestrial and/or other structural panels, and to reduce noise, vibration and harshness for industrial utility. The solar panel electrical terminations may be housed in one or more junction boxes formed from flexible material of the damper, and having simplified electrical connections with strain relief. The solar module with integrated solar panel, damper and junction boxes constitutes a lightweight, durable body panel with a reduced number of components that may be manufactured in high volume and at low cost.