Solar Roof Tile Metal Frame Rubber Layer Weight Reduction
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Solution Overview
Problem
Existing solar tile fixing substrates are either overweight, leading to structural instability and high costs, or underweight, resulting in inadequate load capacity and structural strength, posing safety risks and limiting widespread application.
Innovation Solution
A solar tile design featuring a metal frame with a rubber layer, comprising parallel beams and stringers with arc and horizontal portions for enhanced support strength and stability, connected via hooks for reduced weight and manufacturing costs, along with a weatherability coating and circuit module for efficient power output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the fixing substrate uses a pure-metal structure to meet structural strength and load capacity requirements, then the structural strength is improved, but the weight increases significantly causing large pressure on the roof
Solution Approach 1:
The fixing substrate uses a composite structure combining a metal frame (aluminum alloy or stainless steel) with a polymer layer (PVF or PVDF) cladding. This composite material approach provides sufficient structural strength and load capacity while significantly reducing the overall weight compared to pure-metal structures, thereby reducing pressure on the roof.
Solution Approach 2:
The metal frame is segmented into multiple beams and stringers arranged in a grid pattern. This segmentation allows the structure to achieve required strength through distributed load bearing while using less material overall, reducing weight while maintaining structural integrity.
2Weight of stationary object
If the fixing substrate reduces weight to reduce pressure on the roof, then the weight is reduced, but the structural strength and load capacity become insufficient
Solution Approach 1:
The combination of metal frame and polymer cladding creates a composite structure where the metal provides structural strength and the polymer adds protective and structural contributions, achieving high strength-to-weight ratio that maintains load capacity while reducing overall weight.
Solution Approach 2:
The beams and stringers incorporate arc portions with specific curvature radii (50-150mm for beam arc portions, 30-80mm for stringer arc portions). These curved geometries enhance structural strength and load capacity while using minimal material, optimizing the strength-to-weight ratio.
3Stability of the object's composition
If the fixing substrate uses complex structural design to enhance strength, then the structural stability is improved, but the manufacturing cost increases
Solution Approach 1:
The frame is divided into standardized beams and stringers that can be manufactured separately and assembled. This modular segmentation simplifies manufacturing processes, reduces production costs, while maintaining structural stability through the grid configuration.
Solution Approach 2:
The beams and stringers are designed with universal connection features (arc portions for hooking adjacent components) that allow standardized assembly. This universality simplifies manufacturing and assembly processes, reducing costs while ensuring structural stability through consistent geometric relationships.
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 provides a lightweight, cost-effective solar tile system with improved structural stability, load capacity, and reduced pressure on load-bearing substrates, enhancing safety and performance while maintaining a high performance-to-cost ratio.
Implementation Method 1
solar tiles can be arranged on the roof to convert solar energy into electrical energy for users
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A solar tile comprises a solar panel, a fixing substrate configured to support the solar panel, and a circuit module disposed on the fixing substrate. The fixing substrate comprises a metal frame and a rubber layer cladding the metal frame. The solar panel is fixedly stacked on the fixing substrate. The metal frame is capable of providing the solar tile with sufficient support strength, and the inner of the metal frame has great mutual restraint and containment forces, such that the metal frame has great impact resistance. Because the fixing substrate only comprises the metal frame and the rubber layer, the weight thereof is greatly reduced compared with a pure-metal structured fixing substrate. In addition, because the fixing substrate is made of less amount of metal material and has simple structure, the cost for manufacturing is reduced.