Composite Solar Panel Laminate for Thermal Expansion Matching
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Solution Overview
Problem
Solar panels in vehicles face thermal stress due to mismatched coefficients of thermal expansion (CTE) between glass and laminate materials, leading to deformation and potential shattering, especially under extreme temperature variations.
Innovation Solution
A composite hybrid laminate with a central layer of carbon and glass fibres, embedded in a cured polymer, is used to match the CTE of soda-lime glass, ensuring isotropic stiffness and strength, and reducing thermal residual stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional laminate is used to strengthen the solar panel, then the structural strength is improved, but the coefficient of thermal expansion mismatch causes deformation and stress under temperature variations
Solution Approach 1:
The patent employs a composite laminate structure consisting of multiple layers with different materials (glass fiber reinforcement, polymer matrix) to achieve a coefficient of thermal expansion that matches glass while maintaining high structural strength. The composite nature allows tuning of thermal and mechanical properties to resolve the contradiction between strength and dimensional stability.
Solution Approach 2:
The patent modifies the laminate's coefficient of thermal expansion by adjusting the composition, orientation, and arrangement of fiber plies within the laminate. By changing these parameters, the laminate's thermal expansion characteristics are tailored to match glass, eliminating differential expansion stress while preserving structural integrity.
2Area of stationary object
If the glass plate is curved in two directions for vehicle application, then the solar panel area is maximized, but the thermal stress and deformation risk increase
Solution Approach 1:
The composite laminate provides enhanced mechanical support and thermal expansion matching that is particularly important for curved surfaces. The multi-layer composite structure accommodates the complex stress states in doubly curved geometry while maintaining dimensional stability under thermal loading.
Solution Approach 2:
The laminate structure is designed with specific fiber orientations and layer configurations that address the local stress and thermal expansion requirements of curved surfaces. Different regions of the laminate can have optimized properties suitable for their specific location on the curved glass plate.
3Weight of moving object
If the laminate is made lighter for vehicle application, then the vehicle weight is reduced, but the robustness and impact resistance may be compromised
Solution Approach 1:
The composite laminate achieves high strength-to-weight ratio through optimized fiber reinforcement and polymer matrix combination. The glass fiber reinforcement provides high strength and stiffness with low density, while the polymer matrix binds the fibers and distributes loads, achieving both light weight and high impact resistance.
Solution Approach 2:
The laminate structure is designed to work with the curved geometry of the solar panel, where the curved shape itself provides structural strength. The laminate follows the curvature and provides reinforcement that enhances impact resistance while maintaining the lightweight advantage of composite materials.
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 solution effectively minimizes thermal deformation and stress in solar panels, maintaining structural integrity and safety across a wide temperature range, while being lightweight and cost-effective.
Implementation Method 1
the plies embedded in a cured polymer
Implementation Method 2
a small difference in the coefficient of thermal expansion (CTE) of the glass and the composite laminate can lead to unacceptable deformation and stresses
Data Source
AI summary
The invention relates to a solar panel backed by a laminate with a coefficient of thermal expansion closely matching that of soda-lime glass. Optionally, the solar panel comprises a soda-lime glass plate, a low CTE epoxy resin with a CTE of less than 50 ppm/K at room temperature, an upper layer and a lower layer each comprising two woven E-glass fibres and 33% resin weight, the E-glass fibres having an estimated Young's modulus in the x-direction and y-direction for a woven ply with x and y aligned in the two fibre directions of 26.3 GPa for each ply, and an estimated CTE of 13.3 ppm/K, having a thickness of between 0.7 and 1.4 times the thickness of the central layer, and a central layer comprising woven carbon fibres, 42% resin weight, and having an estimated Exx and Eyy of 62.8 GPa, as well as an estimated CTE of 1 ppm/K.