Patent Publication Number: US-2018029544-A1

Title: Roof support structure for solar panel module

Description:
TECHNICAL FIELD 
     This disclosure relates to a roof support structure for solar panels attached to a vehicle roof panel. 
     BACKGROUND 
     Certain vehicles may be equipped with a sunroof or moon roof. These additional features require adaptation and attachment to the roof panel. 
     SUMMARY 
     A vehicle includes a roof panel defining an opening, a support structure and a solar panel module. The support structure is attached to the roof panel and disposed within the opening. The support structure includes first and second sections, at least two leg portions, and a divider disposed between the leg portions and separating the first and second sections. The first section is defined between the leg portions and the divider, and the second section is defined between the leg portions and the divider disposed adjacent the first section. The solar panel module is disposed within the first or second section. The solar panel module includes a solar array adhered, via an electrical discharge film, to a plate having a plurality of ribs extending over an area of the solar array. The ribs have a V-shaped cross-section spaced throughout the area to support the solar panel module within the support structure. 
     A vehicle roof panel includes a support structure and a solar panel module. The support structure has a first section defined by an outer periphery of the support structure. The solar panel module is disposed within the first section, and includes a solar array adhered to a plate having a plurality of ribs extending over an area of the solar array. The ribs have a V-shaped cross-section spaced throughout the first section to support the solar panel module within the support structure. 
     A support structure for a vehicle roof panel includes a solar panel module. The solar panel module is disposed within an opening defined by an outer periphery of a support structure. The solar panel module includes a first part configured to slide underneath a second part containing a solar array adhered to a plate. The plate has a plurality of ribs extending across the solar array. The ribs have a V-shaped cross-section to support the solar panel module within the second part. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a vehicle with a solar panel module on a roof panel; 
         FIG. 2  is a perspective view of the vehicle roof panel and a support structure to support a moon roof and the solar panel module; 
         FIG. 3  is a cross-sectional view taken along the lines  2 - 2  of  FIG. 2  of the support panel module; and 
         FIG. 4  is a cross-sectional view taken along the lines  2 - 2  of  FIG. 2  of a further embodiment of the solar panel module. 
     
    
    
     DETAILED DESCRIPTION 
     Embodiments of the present disclosure are described herein. It is to be understood, however, that the disclosed embodiments are merely examples and other embodiments may take various and alternative forms. The figures are not necessarily to scale; some features could be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention. As those of ordinary skill in the art will understand, various features illustrated and described with reference to any one of the figures may be combined with features illustrated in one or more other figures to produce embodiments that are not explicitly illustrated or described. The combinations of features illustrated provide representative embodiments for typical applications. Various combinations and modifications of the features consistent with the teachings of this disclosure, however, could be desired for particular applications or implementations. 
       FIG. 1  depicts a perspective view of a vehicle  10  having a roof panel  12  defining an opening  14 . The vehicle  10  also includes a support structure  16  disposed within the opening  14  attached to the roof panel  12  and a solar panel module  18 . The solar panel module  18  attaches to the roof panel  12  via the support structure  16 . The solar panel module  18  comprises a solar array  20 . The solar array  20  is configured to convert radiation energy into electrical energy for use with the vehicle  10 . The solar array  20  uses a plurality of solar cells  22  connected in series to convert radiation energy into electrical energy for the vehicle  10 . For example, the solar panel module  18  via the solar array  20  can be used as an accessory power source for charging a battery  24  within the vehicle  10  using a charge controller  27 . The battery  24  may include any device capable of storing charge from the solar panel module  18  such as, but not limited to, lithium-ion batteries, nickel cadmium batteries, nickel metal hydride batteries, lead acid batteries, or lithium polymer batteries. The battery  24  may also include a single battery  24 , or multiple batteries  24  configured to power tools, laptops, air compressors, lights, or any other instrument or device commonly used by passengers within the vehicle  10 . 
     Powering accessory devices within the vehicle  10  results in poor fuel economy. For example, the vehicle  10  needs to run an engine  26  in order to provide power to various accessory devices within the vehicle  10  or used by the vehicle  10 , such as lights, wipers, or E bikes. Providing power through the solar panel module  18  to the devices allows the vehicle  10  to increase fuel economy by further reducing combustion through the engine  26  by removing the need for the vehicle  10  to idle. Likewise, an internal battery  28  may be used to power other components within the vehicle  10 , such as a motor generator  30 . The solar panel module  18  allows the internal battery  28  of the vehicle to power the motor generator  30  for an extended time. When the vehicle  10  is being powered by the motor generator  30 , combustion through the engine  26  is not required. Therefore, the solar panel module  18  may allow the vehicle  10  to have an extended range using the motor generator  30  and further improve fuel economy. The solar panel module  18  may also be configured to power the internal battery  28  in order to increase the travel time and range of the motor generator  30  for the vehicle  10 . 
     As stated above, the solar panel module  18  attaches to the roof panel  12  through the support structure  16 . During normal vehicle operation, the solar panel module  18  may be subject to torsional and bending loads. The support structure  16  allows the solar panel module  18  to be isolated away from direct loading as a result of normal vehicle operation. Isolation and the lack of direct loading on the solar panel module  18  is a result of the support structure  16  interconnecting the solar panel module  18  and the roof panel  12 . The support structure acts  16  as an intermediary between the solar panel module  18  and the roof panel  12  to avoid direct loading on the solar cells  22  and improve efficiency of the solar array  20  during charging as described above. The support structure  16  may attach to the roof panel  12  through fastening and the solar panel module  18  attaches to the support structure  16  via bonding. In at least one other embodiment, the support structure  16  may attach to the roof panel through hemming, welding, or any other method to attach a support structure  16  within an opening  14  on the roof panel  12  and the solar panel module may be attached to the support structure  16  via fastening. 
     As shown in  FIG. 1 , the solar panel module  18  defines the solar array  20  across an entirety of the support structure  16  and likewise the opening  14 . In at least one other embodiment, detailed with reference to  FIG. 2 , the solar array  20  of the solar panel module  18  may be disposed across a first section  32  of the support structure  16 . The solar panel module  18  may further include a first part  34  and a second part  36 . The first part  34  of the solar panel module  18  may be disposed across the first section  32  of the support structure  16  and the second part  36  of the solar panel module  18  may be disposed across a second section  38  of the support structure  16 . The solar panel module  18  including the orientation, layout, and design of the solar array  20  may be optimized based on power consumption and need for the vehicle  10 . 
     Referring to  FIG. 2 , a perspective view of the roof panel  12 , the support structure  16  and the solar panel module  18  including the solar array  20  is depicted.  FIG. 2  depicts the second part  36  of the solar panel module  18  disposed within the second section  38  of the support structure  16  and the first part  34  of the solar panel module  18  slid underneath the second part  36 . The support structure  16  defines an outer periphery  40  within the opening  14  of the roof panel  12 . The outer periphery  40  is bordered by at least two leg portions  42  and a divider  44 . The divider  44  separates the first section  32  from the second section  38  and extends between the at least two leg portions  42 . The first part  34  is defined between the first section  32  and the divider  44  and the second part  36  is defined between the second section  38  and the divider  44 . 
     As described above, the solar panel module  18  may define a first part  34  disposed in a first section  32  of the support structure and a second part  36  disposed in a second section  38  of the support structure  16 . In at least one other embodiment, the first part  34  may be disposed in the first section  32  of the support structure  16  and a windowpane  50  may be disposed in the second section  38  of the support structure  16 . Likewise, the second part  36  may be disposed in the second section  38  of the support structure  16  and the windowpane  50  may be disposed in the first section  32  of the support structure  16 . Placing the windowpane  50  in either the first or second sections  32 ,  38  of the support structure  16  allows the roof panel  12  to define a moon roof for the vehicle  10 . 
     The support structure  16  they further include a track  52 . The track  52  may be defined in line and adjacent the at least two leg portions  42 . The track  52  allows the first part  34  of the solar panel module  18  to slide underneath the second part  36  of the solar panel module  18 . Therefore, after sliding, the first part  34  may be disposed underneath the second part  36 . When the first part  34  is disposed underneath the second part  36 , the solar panel module  18  may be defined entirely within the second section  38  of the support structure  16 . The track  52  may also allow the second part  36  of the solar panel module  18  to slide underneath the first part  34  such that the entire solar panel module  18  may be defined entirely within the first section  32  of the support structure  16 . 
     If the windowpane  50  is disposed within the first or second sections  32 ,  38 , the windowpane  50  may be configured to slide along the track  52  to define a sunroof within either the first or second sections  32 ,  38 . For example, if the windowpane  50  is disposed within the first section  32  of the support structure  16 , the second part  36  of the solar panel module  18  may be disposed in the second section  38  of the support structure  16  and the windowpane  50  may be configured to slide along the track  52  underneath the second part  36  of the solar panel module  18 . Likewise, if the windowpane  50  is disposed within the second section  38  of the support structure  16 , the first part  34  of the solar panel module  18  may be disposed within the first section  32  of the support structure  16  and the windowpane  50  may be configured to slide along the track  52  underneath the first part  34  of the solar panel module  18 . 
     The windowpane  50  is configured to slide along the track  52  underneath either the first part  34  or the second part  36  of the solar panel module  18  for increased efficiency of the solar panel module  18 . By sliding underneath the first or second parts  34 ,  36 , the windowpane  50  avoids potential obstruction or distortion of the light absorption by the solar panel module  18  to increase the energy absorbed by the solar panel module  18 . In at least one other embodiment, the windowpane  50  may be configured to slide along the track  52  to a position above either the first part  34  or the second part  36  of the solar panel module  18  if the windowpane  50  is disposed within the first section  32  or the second section  38  of the support structure  16 , respectively. If the windowpane  50  is configured to slide above the solar panel module  18 , the windowpane  50  may provide further protection to the solar panel module  18 . 
     Referring to  FIGS. 3 and 4 , a cross-sectional view of the solar panel module  18  attached to the support structure  16  is shown. For example, the solar panel module  18  further includes a housing  54 , a plate  56  and a bracket  58 .  FIG. 3  depicts a first embodiment of the solar panel module  18  and  FIG. 4  depicts a second embodiment of the solar panel module  18 . The first embodiment, shown in  FIG. 3 , allows the plurality of solar cells  22  to be exposed to radiation energy directly on the vehicle  10  whereas the second embodiment, shown in  FIG. 4  covers the plurality of solar cells  22 . 
     While shown and described as single and different embodiments, the solar panel module  18  may incorporate one or both of the first and second embodiments. For example, in the embodiment in which the solar panel module  18  has a first part  34  disposed in the first section  32  of the support structure  16  and the second part  36  is disposed in the second section  38  of the support structure  16 , the first part  34  may include the embodiment shown and described in  FIG. 3  and the second part  36  may include the embodiment shown and described in  FIG. 4 . Likewise, for example, the first and second parts  34 ,  36  of the solar panel module  18  may both include the embodiment shown in either of  FIG. 3 or 4 . Utilizing the embodiment shown in  FIGS. 3 and 4 , either individually or in combination, may depend on a variety of factors including, but not limited to, cost, weight and efficiency of the solar panel module  18 . 
     Referring to  FIG. 3 , a cross-sectional view of the first embodiment of the solar panel module  18  is shown. As stated above, the solar panel module  18  includes a housing  54 , a plate  56  and a bracket  58 . The bracket  58  attaches to the plate  56 . In at least one embodiment, the bracket  58  may be spot welded to the plate  56 . In at least one other embodiment, the bracket  58  may be attached to the plate  56  using adhesive, fasteners, or any other attachment method. The bracket  58  attaches to the support structure  16  in order to maintain the solar panel module  18  and the first or second sections  32 ,  38  of the support structure  16 , as described above. The bracket  58  allows a support structure  16  to support the solar panel module  18  on the roof  12  the vehicle  10 . 
     The plate  56  is disposed between the bracket  58  and the housing  54  and supports the solar panel module  18 . Specifically, the plate  56  is configured to support the solar array  20  including the plurality of solar cells  22 . The solar array  20  is adhered to the plate  56  using an electrical discharge film  23 . The plate  56  includes a first end  60  and a second and  62 . The first end  60  is disposed opposite the second end  62 , wherein the first and second ends  60 ,  62  are disposed across the solar array  20 . Therefore, the plate  56  extends across and over an area  64  defined by the solar array  20  between the first and second ends  60 ,  62 . The plate  56  may further include a plurality of ribs  66 . The plurality of ribs  66  extends across the area  64  defined by the solar array  20  and is disposed underneath the solar array  20 . The plurality of ribs  66  extends across the plate  56  between first and second ends  60 ,  62  and is centered on the solar cells  22  of the solar array  20 . 
     Centering the ribs  66  on the solar cells  22  provides optimal support for the solar array  20  over the area  64  between the first and second ends  60 ,  62  of the plate  56 . The plurality of ribs  66  provide added stiffness to the plate  56  to further support the solar array  20  of the solar panel module  18  within the support structure  16 . The plurality of ribs  66  defines a substantially V-shaped cross-sectional area  68 . For example, each rib  70  of the plurality of ribs  66  includes a first and second side  72 ,  74  that culminate in an apex  76  to form a V-shape. The V-shape of the ribs  66  provides the required stiffness and rigidity of the plate  56  over the area  64  defined by the solar array  20  between the first and second ends  60 ,  62 . Further, the plurality of ribs  66  may be cross patterned across the plate  56 . Cross patterning the ribs  66  across the area  64  between the first and second ends  60 ,  62  further aids the plate  56  to support the solar array  20  across the plate  56 . As will be described in more detail below, the V-shape cross-sectional area  68  of the plurality of ribs  66  also aids to improve cooling of the solar cells  22 . The apex  76  of the plurality of ribs  66  may be defined in a direction away from the solar array  20 . Therefore, air flow may be directed under the plurality of solar cells  22  and away from the solar array  20  using the plurality of ribs  66 . In at least one other embodiment, the plurality of ribs  66  may define a substantial U-shape, W-shape, or any other shape that allows the plate  56  be added support and stiffness for the solar array  20 . 
     The apex  76 , formed from the first and second sides  72 ,  74  includes an angle α. The size of the first and second sides, including the length of the sides  72 ,  74  may be optimized based on various vehicle characteristics, such as size, weight and stiffness required to support the solar panel module  18 . Further, the angle a may also be optimized depending on the support required for optimal use of the solar panel module. For example, larger vehicles may require a larger and heavier solar panel module and the sides  72 ,  74  and the angle α of the plurality of ribs  66  may be designed to support a larger solar panel module  18  without impacting performance of the solar panel module  18 . Likewise, small vehicles may require a smaller and lighter solar panel module  18  and the sides  72 ,  74  and the angle α of the plurality of ribs  66  may be designed to support a smaller solar panel module  18  without impacting performance of the solar panel module  18 . Again, the sides  72 ,  74  and the angle α may be based on the packaging space available for the support structure  16  and solar panel module  18 . 
     The first and second ends  60 ,  62  of the plate  56  may be turned down for added stiffness of the plate  56 . For example, the first and second ends  60 ,  62  may be substantially perpendicular to the area  64  defined by the solar array  20  and substantially parallel to the bracket  58 . The first and second ends  60 ,  62  may also be substantially parallel to the apex  76  of the plurality of ribs  66 . Therefore, the first and second ends  60 ,  62  of the plate  56  provide further stiffness to the plate such that the solar array  20  extends across the area  64  in a substantially planar orientation. The plate  56  may be stamped aluminum and range in thickness from 0.8 millimeters to 1.2 millimeters. In at least one other embodiment, the plate  56  may be e-coated steel, or any other material configured to support the solar array  20  using the plurality of ribs  66 , as described above. 
     Maintaining a substantially planar orientation of the solar array  20  ensures efficient absorption of radiation energy from the plurality of solar cells  22 . For example, by eliminating sag within the plate  56 , via the plurality of ribs  66 , the solar array remains relatively flat across the plate  56  such that a maximum of the plurality of solar cells  22  remains substantially perpendicular to incident radiation for energy absorption. Further, absorption of radiation energy using the plurality of solar cells  22  may also cause the plurality of solar cells  22  to absorb heat. The plurality of ribs  66  and, therefore, the plate  56  may further aid to direct the heat flow away from the plurality of solar cells  22 . For example, the plurality of ribs  66  may act as a plurality of cooling fins to pull heat due to incident radiation energy absorption from the solar cells  22  and direct the heat across the plate  56  to the first and second ends  60 ,  62 , detailed below. The plurality of ribs  66  increase the surface area of the plate  56 , which allows the plate  56  to be thinner improving the thermal conductivity through the plate and away from the solar array  20 . 
     The housing  54  is configured to attach to the plate  56 . The housing  54  further aids to seal the plate  56  as well as the solar array  20  to prevent moisture from corroding the plate  56  or damaging the solar array  20 . The housing  54  is configured to surround the solar array  20  and includes a first seal  78  disposed at the first end  60  of the plate  56  and a second seal  80  disposed at the second end  62  of the plate  56 . The first and second seals  78 ,  80  may be composed of rubber such that the first and second seals  78 ,  80  further aid to damp vibrations across the solar array  20  during normal vehicle operation. The first and second seals  78 ,  80  may be adhered to the housing  54  using a pressure sensitive tape  82 . The pressure sensitive tape  82  ensures that the solar array  20  is properly sealed by the first and second seals  78 ,  80  without damaging the solar array  20 . To account for moisture that may pool or may fall past the first or second seals  78 ,  80 , the housing  54  may further include a water management system (not shown) typically used for moon roof frames. The water management system (not shown) may include troughs (not shown) to route the moisture to the first and second ends  60 ,  62  of the plate  56  and into drain tubes (not shown), which route and move the moisture back to the external environment and under the vehicle  10 . 
     Further, the solar array  20  may be protected using a film  84 . The film  84  may be a clear and protective film  84  to cover the plurality of solar cells  22  and protect plurality of solar cells  22  from damage due to weather, use or operation of the vehicle  10 . The film  84  attaches to the housing  54  between the plate  56  and the first and second seals  78 ,  80  at the first and second ends  60 ,  62  of the plate  56 . The film  84  adheres to the solar array  20  and the plate  56  with adhesive on one side of the film  84 . Only using adhesive on one side of the film  84  allows the film  84  to be as clear as possible. When the film  84  as clear as possible, light and therefore radiation easily passes through the film  84  and can be absorbed by the solar array  20 . Further, when the film  84  is clear, the film  84  is better able to withstand discoloration associated with UV ray affect. 
     The film  84  is configured to protect the solar array  20  across the area  64  defined by the solar array within the housing  54 . The film  84  may be an ethylene vinyl acetate film  84 . The ethylene vinyl acetate film  84  may be heat cured to laminate the plurality of solar cells  22 . Laminating the plurality of solar cells  22  allows the film  84  to provide a vacuum-tight seal around the plurality of solar cells  22  to inhibit moisture from contacting the plurality of solar cells  22  as well as protecting the plurality of solar cells  22  as described above. The film  84  may be any elastomeric polymer that maintains good clarity, hot-melt adhesive and waterproof properties, and UV radiation resistance. The solar array  20  may be completely covered across the area  64  by the film  84  to provide further isolation from damage or corrosion via the film  84  and the first and second seals  78 ,  80  due to normal operational use of the vehicle  10 . 
       FIG. 4  depicts a cross-sectional view of the second embodiment of the solar panel module  18 . The second embodiment of the solar panel module  18  still includes the housing  54 , the plate  56  and the bracket  58 . Further, the second embodiment of the solar panel module  18  still uses a plurality of ribs  66  on the plate  56  over the area  64  defined by the solar array  20  to support the solar array  20  and prevents SAG within the solar panel module  18  to maximize absorption of radiation energy by the plurality of solar cells  22 . Likewise, the housing  54  surrounds the area  64  and seals moisture from the solar array  20  using the first and second seals  78 ,  80 , as described above. The solar array  20  is still adhered to the plate  56  using an electrical discharge film  23 . The film  84  still covers the area  64  defined by the solar array  20  to protect and seal the solar array  20 . 
     In the second embodiment, the solar panel module  18  further includes at least one vent  86 , and adapter  88  and the cover  90 . The at least one vent  86  is defined in the plate  56 . The at least one vent  86  may be defined on either the first and  60  or the second end  62  of the plate  56 . In at least one other embodiment, the plate  56  may define two vents  86  defined on both the first end  60  in the second and  62 . The vent  86  aids to dissipate heat from the solar array  20  via the plate  56  and the plurality of ribs  66 , as described above. To maintain optimal performance of the solar array  20 , the vent  86  allows heat to escape from the solar panel module  18  to avoid overheating of the solar array  20 . The vent  86  is defined on the plate  56  near the bracket  58  to avoid sacrificing rigidity of the plate  56  and therefore the solar panel module  18 . Further, the vent  86  is defined within the housing  54  to maintain the first and second seals  78 ,  80  such that moisture is inhibited from contacting the solar array  20 . Again, the at least one vent  86  may aid the solar array  20  and absorbing radiation and converting radiation energy to electrical energy by dissipating unnecessary heat away from the solar array  20 . 
     The cover  90  extends across the area  64  defined by the solar array  20  to further protect and seal the solar array  20 . The cover  90  may be in addition to the film  84 . The cover  90  may be semi-tempered or annealed glass to provide further protection of the plurality of solar cells  22 . Again, as stated above, the cover  90  needs to be clear in order to avoid distortion of the radiation energy through the cover  90  before absorption by the plurality of solar cells  22 . Likewise, the cover  90  may be used on either of the first part  34 , the second part  36  or both the first and second parts  34 ,  36  of the solar panel module  18  as described above. The cover  90  extends from the first end the  60  of the plate  56  to the second and the  62  of the plate  56  and attaches to the housing  54  at both the first and second ends  60 ,  62 . Again, the pressure sensitive tape  82  adheres to the housing  54  and the cover  90  to provide attachment between the housing  54  and the cover. The pressure sensitive tape  82  also provides sealing of the solar panel module  18  to inhibit moisture or other corrosive fluid from contacting the solar array  20 . 
     The adapter  88  extends between the plate  56  and the cover  90 . The adapter  88  provides a bonding interface between the cover  90  and the plate  56 . The adapter  88  provides an extension of the plate  56  to account for a combined thickness  92  of the solar array  20  with the film  84  up to the cover  90 . Specifically, the adapter  88  defines a height  94  to attach the cover  90  to the plate  56  and avoid pressure on the solar array  20  from the cover  90 . The adapter  88  does not significantly increase the size of the solar panel module  18 . For example, the housing  54  may still be configured to wrap around the solar array  20  and the first and second seals  78 ,  80  may still be configured to attach to the first and second ends  60 ,  62  of the plate  56 . Addition of the adapter  88 , and therefore the cover  90 , requires no further modification of the solar panel module  18 . Adaptation of the solar panel module  18  without significant modification to the solar panel module  18  allows for the interchangeability of the embodiment shown and discussed in  FIG. 3  and the embodiment shown and discussed in  FIG. 4 , as detailed above. Each embodiment may be used individually, or in conjunction with the other depending on the use circumstances described above. 
     While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms encompassed by the claims. The words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the disclosure. As previously described, the features of various embodiments may be combined to form further embodiments of the invention that may not be explicitly described or illustrated. While various embodiments could have been described as providing advantages or being preferred over other embodiments or prior art implementations with respect to one or more desired characteristics, those of ordinary skill in the art recognize that one or more features or characteristics may be compromised to achieve desired overall system attributes, which depend on the specific application and implementation. These attributes may include, but are not limited to cost, strength, durability, life cycle cost, marketability, appearance, packaging, size, serviceability, weight, manufacturability, ease of assembly, etc. As such, embodiments described as less desirable than other embodiments or prior art implementations with respect to one or more characteristics are not outside the scope of the disclosure and may be desirable for particular applications.