Vehicle Body Photovoltaic Module Encapsulation in Thermoplastic Molding
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Solution Overview
Problem
Existing vehicle-mounted photovoltaic systems increase weight, wind resistance, and fuel/power consumption, and are limited in area integration, particularly on electric vehicles where larger power generation areas are needed without affecting appearance or performance.
Innovation Solution
A method for fabricating photovoltaic modules integrated into vehicle body components like hoods, doors, and roofs using a thermoplastic molding process that encapsulates photovoltaic modules within the vehicle shell, reducing weight and wind resistance while maintaining appearance and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If photovoltaic modules are installed on brackets or directly pasted on the roof or body, then photovoltaic power generation is achieved, but the appearance is affected and the weight increases leading to increased fuel consumption
Solution Approach 1:
The patent merges the photovoltaic module with the vehicle body component by integrating the module directly into the molding process of the body part. The photovoltaic module is embedded within the thermoplastic material during injection molding, eliminating the need for separate brackets or mounting structures. This integration reduces device complexity while maintaining power generation functionality.
Solution Approach 2:
The vehicle body component serves multiple functions: it acts as both the structural body part and the mounting structure for the photovoltaic module. The thermoplastic material encapsulates the module while forming the functional body component, making the body part universal in its role rather than requiring separate dedicated mounting hardware.
2Adaptability or versatility
If photovoltaic cells are encapsulated with double-layer glass to form roof skylights, then photovoltaic integration is achieved, but the application is limited only to the roof area
Solution Approach 1:
The patent changes the material parameter from rigid double-layer glass to flexible thermoplastic material. This parameter change enables the photovoltaic module to be integrated into various vehicle body components with different shapes and curvatures, not limited to flat roof surfaces. The thermoplastic material can be molded into complex geometries, expanding adaptability to hoods, doors, and other body parts.
3Shape
If photovoltaic modules are integrated into the vehicle body, then appearance is maintained and weight is reduced, but the battery cooling-induced internal stress may cause deformation
Solution Approach 1:
The patent uses composite material construction where the thermoplastic material encapsulates the photovoltaic module, creating a composite structure. This composite design provides mechanical support and stress distribution, helping the integrated module resist deformation from thermal stresses generated by battery cooling operations while maintaining the vehicle body's appearance.
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
Enables full integration of photovoltaic power generation across larger vehicle areas without increasing fuel or power consumption, reducing battery stress and deformation risks, and applying to larger-sized vehicle bodies.
Implementation Method 1
the two pieces of the first thermoplastic material and the second thermoplastic material forming the components of the vehicle body are preheated to soften them
Implementation Method 2
The upper mold and the lower mold are driven to mold. The photovoltaic module is encapsulated into the first thermoplastic material and the second thermoplastic material under the operation of the high temperature and high pressure
Implementation Method 3
after the first thermoplastic material and the second thermoplastic material are cooled and shaped, the upper mold and the lower mold are separated to obtain a semi-finished product
Data Source
AI summary
A fabrication method prepares a photovoltaic module integrated with a vehicle body. A mold includes an upper mold and a lower mold, the upper surface of the upper mold is a first forming surface, and the lower surface of the lower mold is a second forming surface; then, the two pieces are formed into a first thermoplastic material and a second thermoplastic material of a vehicle body element; the first thermoplastic material and the second thermoplastic material are moved to be between the upper mold and the lower mold; the first thermoplastic material and the second thermoplastic material are made to attach to the second forming surface and the first forming surface, respectively; the upper mold and the lower mold are driven to close, and a photovoltaic module is packaged into the first thermoplastic material and the second thermoplastic material and a finished product is obtained after cooling and shaping.