Portable Solar Panel Coating Applicator for Uniform On-Site Deposition
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Solution Overview
Problem
Existing methods for applying anti-reflective coatings on large solar panels are inefficient, leading to non-uniform coatings and material waste, and require costly and damaging transportation and reassembly processes for existing panels.
Innovation Solution
A portable coating device that includes a supply module, a base with a spraying module, a transmission module, an arc bracket with seepage openings, and an applicator with a deformable porous material, allowing for on-site application of coatings directly onto solar panels without disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If blade coating, spin coating or vacuum deposition is used for large solar panels, then coating can be applied, but the coating uniformity deteriorates and material waste increases
Solution Approach 1:
The coating solution is sprayed onto the arc bracket, which then automatically seeps through the porous material of the applicator by capillary action. The system uses its own structure (porous material with controlled porosity) to distribute the coating solution uniformly without requiring additional complex distribution mechanisms, achieving both uniformity and material efficiency
Solution Approach 2:
The applicator employs a porous material with specifically controlled porosity (30-70%) that allows the coating solution to seep through uniformly via capillary action. This porous structure ensures even coating distribution across the solar panel surface while minimizing material waste through controlled absorption and release
2Ease of manufacture
If solar panels are removed from working environment for coating application, then coating can be applied, but production cost increases and damage risk increases
Solution Approach 1:
The portable coating device is brought to the solar panel's location in the field, and coating application is performed in situ before the panel returns to service. This preliminary action at the installation site eliminates the need for transportation and reassembly, preventing damage while maintaining manufacturing capability
Solution Approach 2:
Instead of removing the solar panel from the field to a factory for coating (traditional approach), the invention inverts the process by bringing the coating device to the solar panel in the field. This reversal of locations eliminates transportation risks and enables coating application without disassembly
3Area of stationary object
If existing coating methods are used for large area solar panels, then coating can be applied, but the coating uniformity deteriorates
Solution Approach 1:
The coating application process is segmented into discrete spray zones along the arc bracket, with multiple nozzles covering different sections. The porous material further segments the coating solution distribution at a micro level, ensuring uniform coverage across large areas through distributed, controlled release points
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 portable device ensures effective and uniform application of coatings on solar panels, reducing material waste and production costs, while allowing for direct application on existing panels without damage or increased expense.
Implementation Method 1
the applicator includes a porous material that deforms under pressure... the coating solution seeps to the applicator through the seepage openings to be adsorbed by the applicator
Implementation Method 2
the arc bracket is disposed at a bottom of the base and has multiple seepage openings... the coating solution seeps to the applicator through the seepage openings
Data Source
AI summary
A portable coating device for applying a coating solution onto a solar panel includes a supply module for supplying the coating solution, a base, a spraying module disposed on the base, a transmission module disposed at two opposite ends of the base, an arc bracket, and an applicator. The base spans the solar panel and moves thereon through the support of the transmission module. The arc bracket is disposed at the bottom of the base and has a plurality of seepage openings, and an inner surface of the arc bracket faces the spraying module. The applicator includes a porous material that deforms under pressure. The applicator is assembled to the base and supported by the arc bracket.