Solar panel and car roof
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Solution Overview
Problem
Existing methods for integrating solar panels into car roofs face issues such as defects during installation, inadequate waterproofing, and the need for separate mechanical fixing structures, which can lead to vibration-related reliability concerns and aesthetic impacts.
Innovation Solution
A solar panel design featuring a first substrate on one surface and a second substrate, typically a steel plate or fiber-reinforced plastic, with encapsulants between the substrates and the solar cell, eliminating the need for a separate mechanical fixing structure and ensuring waterproofing by adhering encapsulants to the entire surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate mechanical fixing structure is used to fix the solar panel to a car roof, then the solar panel can be securely attached, but the device complexity increases and the aesthetic appearance is compromised
Solution Approach 1:
The solar panel integrates the fixing structure directly into the substrate that contacts the car roof, merging the solar cell assembly with the mounting structure. This eliminates separate mechanical fixing components while maintaining secure attachment through the substrate's direct contact with the roof surface.
Solution Approach 2:
The substrate serves multiple functions simultaneously: it provides structural support for the solar cell, acts as the fixing mechanism through direct roof contact, and maintains aesthetic appearance by being visible as part of the car body. This multi-functionality eliminates the need for separate dedicated fixing structures.
2Reliability
If a separate mechanical fixing structure is used to fix the solar panel to a car roof, then the solar panel can be securely attached, but the aesthetic appearance is compromised
Solution Approach 1:
The fixing structure is merged with the substrate material itself, making the mounting mechanism indistinguishable from the visible car body surface. The substrate becomes both the structural element and the aesthetic surface, eliminating separate visible fixing components.
3Ease of manufacture
If conventional fixing methods are used, then the solar panel can be installed, but defects may occur during the fixing process and waterproofing is not perfect
Solution Approach 1:
The encapsulant material is applied to cover the entire perimeter of the solar cell assembly, merging the sealing function with the structural bonding function. This continuous encapsulant layer simultaneously provides mechanical attachment and waterproof sealing, eliminating the need for separate gaskets or sealing components.
Solution Approach 2:
The encapsulant acts as a flexible thin film that conforms to the interface between the solar panel substrate and the car roof, providing continuous waterproof sealing. This film-like encapsulant material flexes with thermal expansion and vibration while maintaining the seal, preventing water infiltration.
4Ease of manufacture
If conventional fixing methods are used, then the solar panel can be installed, but defects may occur during the fixing process
Solution Approach 1:
The fixing and sealing functions are merged into a single encapsulant application process, reducing the number of discrete installation steps. The encapsulant simultaneously bonds the substrate to the roof and seals the interface, eliminating multiple operations that could introduce defects.
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
This design reduces installation defects, prevents water leakage, enhances long-term reliability by absorbing vibrations, and maintains the car's aesthetic appearance while eliminating the need for additional fixing structures.
Implementation Method 1
A solar cell is configured to convert light energy into electric energy. In general, a solar cell includes a P type semiconductor and an N type semiconductor, and when the solar cell receives light, electric charges migrate to cause a potential difference.
Implementation Method 2
A first encapsulant may be disposed between the first substrate and the solar cell and a second encapsulant may be disposed between the second substrate and the solar cell. at least one of the first encapsulant and the second encapsulant can be adhered to the entire adhering surface of the first substrate or the entire adhering surface of the second substrate
Data Source
AI summary
A solar panel can include at least one solar cell having a first surface and a second surface facing in mutually opposing directions; a first substrate disposed on the first surface of the at least one solar cell; a first encapsulant disposed between the first substrate and the at least one solar cell; a second substrate disposed on the second surface; and a second encapsulant disposed between the second substrate and the at least one solar cell, in which the second substrate includes a steel plate or fiber reinforced plastic.