Staggered Solar Panel Cover Plates for Seamless Roof Integration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional solar panel modules cannot be easily connected aesthetically and watertight to form a continuous surface, requiring space between modules and not suitable for integration into building roofs without creating gaps and an uneven appearance.
Innovation Solution
The solar panel modules feature staggered cover plates with overlapping edges to form a seamless, watertight connection, allowing multiple modules to be linked together with minimal gaps, and include a circumferential seal and recesses for electrical connections to ensure airtight and liquid-tight sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional solar panel modules are placed on a surface, then they can be installed on roofs or other surfaces, but space must be kept between modules for edges which creates gaps and prevents aesthetic continuous surfaces
Solution Approach 1:
The solar panel module is divided into a main body portion and extended edge portions. The extended edge portions protrude beyond the main body and are designed to overlap with adjacent modules, creating interlocking connections. This segmentation allows modules to be connected edge-to-edge without gaps while maintaining structural integrity and aesthetic continuity.
Solution Approach 2:
The extended edge portions of adjacent solar panel modules are designed to overlap and nest together, similar to nested dolls or roof tiles. When modules are installed adjacent to each other, the extended edges interlock, eliminating gaps and creating a seamless continuous surface while simplifying the connection structure.
2Shape
If solar panel modules are connected with minimal gaps, then an aesthetically homogeneous surface is achieved, but waterproofing and sealing become more challenging
Solution Approach 1:
The extended edge portions are equipped with specific sealing features including grooves, channels, and sealing elements at the overlapping edges. These local sealing structures are positioned precisely where water penetration is most likely to occur, providing targeted waterproofing without compromising the overall aesthetic homogeneity of the minimal-gap connection.
3Ease of manufacture
If staggered cover plates are used to enable easy connection of multiple plates, then continuous composite panels are achieved, but the manufacturing complexity increases
Solution Approach 1:
The cover plates are designed with asymmetric extended portions that protrude in specific directions. This asymmetric configuration is optimized for the intended installation pattern, allowing modules to be easily connected in a staggered arrangement while simplifying the overall assembly process. The asymmetric design ensures proper alignment and interlocking without requiring complex adjustment mechanisms.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a solar panel module comprising a first and a second cover plate as well as at least one photovoltaic cell located between the cover plates. The first cover plate and the second cover plate are staggered with respect to each other, wherein a portion of the first cover plate near a first longitudinal side extends beyond a first longitudinal side of the second cover plate, while a portion of the second cover plate near a second longitudinal side, extending parallel to the first longitudinal side, extends beyond a second longitudinal side of the first cover plate, which is extending parallel to the first longitudinal side. The photovoltaic cell is located between the first longitudinal side of the second cover plate and the second longitudinal side of the first cover plate.