CN104395081A - Improved photovoltaic modules for use in vehicle roofs, and/or methods of making the same - Google Patents

Abstract

The present exemplary embodiment relates to a technique for fabricating an improved photovoltaic (PV) module. In an exemplary embodiment, first and second glass substrates are provided, a PV array is provided between said first and second glass substrates, said first and second substrates are bonded to said The PV arrays are laminated together. In an exemplary embodiment, the PV modules are sized to resemble roof systems (eg, sunroofs) in existing vehicles. In an exemplary embodiment, apertures are configured in the PV module sandwiched between two substrates, the apertures being shaped and spaced in the PV module so as to transmit light into the vehicle at a desired level, But still substantially filled with lamination material and adhesive material used to fix the PV module in the two surrounding substrates.

Description

Improved photovoltaic module for vehicle roofs and/or method for its production

This application is a continuation-in-part (CIP) of US Application No. 12/926,058, filed October 22, 2010, the entire contents of which are hereby incorporated by reference.

technical field of invention

Exemplary embodiments of the present invention relate to an advanced photovoltaic (PV) module for a vehicle roof, and/or a method of manufacturing the same. In particular, exemplary embodiments of the present invention relate to a PV module for use in automobiles, recreational, marine, and/or other vehicles. In an exemplary embodiment, apertures are configured in the PV module sandwiched between two substrates, the apertures are shaped and arranged within the PV module so that light is transmitted into the vehicle at a desired level, and Fully filled with lamination or adhesive material used to secure the PV module to the surrounding two substrates.

BACKGROUND OF THE INVENTION AND SUMMARY OF EXEMPLARY EMBODIMENTS

Photovoltaic (PV) devices are known technology (eg, US Patent Nos. 2004/0261841, 2006/0180200, 2008/0308147; 6,784,361, 6,288,325, 6,613,603, and 6,123,824, the entire contents of which are incorporated herein by reference).

The use of many current PV devices is limited to relatively fixed locations, such as on top of a residence or as part of a larger power plant. In fact, in some cases, skyscrapers are effectively covered with PV cells. In recent years, installation of PV devices to movable devices such as automobiles or ships is being studied. One of the focuses is to mount PV devices on the roof of the car and/or on the sunroof of the car. In addition, a solar roof can be added, for example, to allow the car to run a ventilation system when it is parked in the hot summer sun.

In an exemplary conventional process, glass for a sunroof may be installed in a vehicle as part of an overall manufacturing and/or assembly process. The size and shape of the sunroof can be designed to meet the structural and design specifications of the vehicle in which the sunroof is installed. For example, a sunroof of a vehicle may be curved or flattened according to the vehicle manufacturer's specifications and/or the shape and configuration of the vehicle.

Although the design aspects of the sunroof may be completed prior to final assembly, the vehicle manufacturer still needs to modify the overall design to accommodate the sunroof. For example, it is well known that the addition of a sunroof as a "built-in" structure of a car may require a reduction in the overall headroom available in the cabin. Also, in some cases, the roof may need to be modified to accommodate the sunroof (eg, when the sunroof is in the open position). Changes in vehicle construction may sometimes increase cost and manufacturing complexity.

Typically, equipping a PV device for a vehicle (e.g., as a sunroof attachment) may involve adding a single piece of flat or curved tempered glass, with flat commercial PV devices attached or mounted directly behind the tempered glass (e.g., inside the sunroof). However, there are still problems with this conventional method for attaching PV devices to skylights. For example, the difficulties of adding skylights relate to: the components not necessarily "fitting", making any necessary or desired electrical connections, the size of the PV modules and and/or shape to match the sunroof and/or roof, maintaining the required structural integrity of the roof.

It should be noted that adding a PV device to a conventional glass sunroof may increase the overall weight of the vehicle. The added weight due to attaching the PV device to the window may affect the performance of the vehicle. Thus, the potential utility benefit of providing a PV sunroof may be offset by the added weight of the vehicle due to the addition of PV devices. Also, the extra weight on the roof may increase the car's overall center of gravity. It may cause safety problems (eg, greater risk of tipping over).

In addition, integrating a newly installed PV device into a vehicle's structure may require modification of the vehicle's body, as described above, since it does not necessarily "fit" without modification. For example, a conventional sunroof may fit into the roof when the window is open. However, when the PV device is added, its increased thickness may prevent the modified sunroof from retracting into the body of the roof.

Vehicle manufacturers can make up for the above problems by designing the roof so that the sunroof is connected to the PV device. However, this solution may create more problems. For example, additional modifications to the vehicle body may increase cost and manufacturing complexity. Furthermore, additional body modifications may be made for at least two existing vehicle configurations (eg, one with a sunroof and one without). Further, the added thickness of the PV device may reduce the available headroom in the passenger compartment.

In addition, the supplier of PV devices may not be a general skylight supplier, and the addition of PV devices may require more assembly steps and make the entire manufacturing process more complicated. Not only is the sunroof installed during assembly, the vehicle manufacturer may need to install the sunroof first and then the PV device. It should be noted that this conventional PV installation may require restructuring of the production line.

Post-market installation of PV devices may create additional problems or complications. Addition of PV devices (with corresponding thicknesses) to the windows may require market customization, including expensive re-structuring of the roof, for vehicles already manufactured.

Accordingly, there is ongoing research into an advanced PV technology for vehicle roofs, sunroofs, and/or the like. Additionally, there is a need in the art for an advanced PV module and the like that can be effectively installed with or in place of a sunroof in a vehicle, for example.

In an exemplary embodiment, a method of manufacturing an integrated photovoltaic (PV) module for a vehicle is provided. A first low-iron glass substrate is provided, the first substrate having a thickness of about 1.5-3.5 mm. A second glass substrate is substantially parallel to the first substrate, and the second substrate has a thickness of about 1.5-3.5 mm. A PV array is disposed between the main surface of the first glass substrate and the main surface of the second glass substrate. The first and second substrates are laminated together with the PV array in between. The size, shape and weight configuration of the PV module is formulated according to the predetermined size, shape and weight associated with the vehicle roof.

In an exemplary embodiment, a method of making a vehicle roof integrated PV module is provided. A first glass substrate having a first thickness is provided, and a second glass substrate is substantially parallel to the first substrate and has a second thickness. The second substrate has a higher iron content and lower visible light transmittance than the first substrate. A solar cell group can be interposed between the first and second glass substrates. The first and second glass substrates are laminated together with solar cells therein.

According to an exemplary embodiment, a method of preparing a vehicle is provided. Install the integrated PV module provided above into the vehicle. Vehicles can be cars, trucks, tractors, boats, airplanes, and more.

In an exemplary embodiment, an integrated PV module for replacing an existing skylight is provided. The thickness of the first glass substrate is 1.5-3.5mm. The second glass substrate is substantially parallel to the first substrate and has higher iron content and lower visible light transmittance than the first substrate. A CIGS-based solar cell group is disposed between a major surface of a first glass substrate and a major surface of a second glass substrate, and the thin film solar cell group has electrical leads connected thereto. The first and second substrates are laminated together by PVB. A PVB seals the solar cell array between the first and second substrates, and electrical leads extend through the PVB and out of the integrated PV module. The integrated PV modules are dimensioned structurally similar to existing skylights.

In an exemplary embodiment, PV cell lamination between two glass substrates and two laminate materials may provide safety and aural benefits. Alternatively, or in addition, the laminated PV module can protect the PV cells by UV filters, like mechanical protection.

In an exemplary embodiment, the use of flexible CIGS thin-film PV cells in lamination can make the PV module somewhat similar or identical to the curvature of other vehicle or vehicle roof systems.

In an exemplary embodiment, the integrated PV module may resemble roof glass commonly used in vehicles. The difference is that the PV module contains electrical connections for the PV cells, and the PV cells of the PV module can generate electricity for the vehicle systems.

In an exemplary embodiment, a PV module comprising a glass substrate, PV cells, and lamination may be similar in weight to a standard glass roof system for a vehicle. Further, replacing a standard glass roof system with an integrated PV module can provide safety and efficiency benefits for passengers and vehicles.

In an exemplary embodiment, a method of manufacturing an integrated photovoltaic (PV) module for a vehicle is provided. providing first and second glass substrates; providing a PV module having a plurality of through holes formed therein; laminating the first and second glass substrates with the PV module therein . Wherein, during said lamination, due to the size, shape, and layout of said vias, lamination material is filled into at least said plurality of vias in said PV module. The through-holes collectively have a selected total area to achieve at least a selected target value of visible light transmission through the integrated PV module.

In an exemplary embodiment, there is provided a method of preparing a vehicle, providing an integrated photovoltaic (PV) module prepared by the above method, and installing the integrated PV module into the vehicle.

In an exemplary embodiment, a method of manufacturing a photovoltaic (PV) module is provided. A substrate is provided on which a plurality of solar cells are formed; a grid-shaped conductive material is arranged on the substrate; a plurality of through holes are formed in the substrate, and the pattern thereof is (a) the through holes collectively have selected a certain total area so that the visible light transmittance through the integrated PV module reaches the target value for which the PV module is set, and (b) the through-holes have an aspect ratio and positioning sufficient to make the integrated PV module The laminate material used flows into it and fills the through holes.

In an exemplary embodiment, there is provided an integrated photovoltaic PV module for a vehicle comprising: first and second glass substrates; a PV module comprising a plurality of spaced solar cells and having a plurality of solar cells formed therein through holes, the PV module being inserted between the first and second glass substrates; and a plurality of polywires formed on the substrate between adjacent solar cells. Wherein the PV module is laminated to the first and second substrates, lamination material is filled into the plurality of vias in the PV module due to the size, shape, and layout of the vias. hole. The through-holes collectively have a selected total area to achieve a selected target value of visible light transmission through the integrated PV module.

The features, aspects, advantages, and example embodiments described herein can be combined in any suitable combination or subcombination to achieve further embodiments.

Brief description of the drawings

Hereinafter, the above-mentioned and other features and advantages will be better and more fully understood by describing exemplary embodiments in more detail with reference to the accompanying drawings.

Figure 1 is a cross-sectional view illustrating an exemplary photovoltaic device according to an exemplary embodiment;

Figure 2a is a cross-sectional view illustrating the composition of an exemplary PV module according to an exemplary embodiment;

Figure 2b is a cross-sectional view illustrating the composition of an exemplary PV layer according to an exemplary embodiment;

Figure 3 is a cross-sectional view illustrating an exemplary PV module after bonding according to an exemplary embodiment;

Figure 4a is a cross-sectional view illustrating an exemplary formed glass substrate according to an exemplary embodiment;

Figure 4b is a cross-sectional view illustrating an exemplary formed glass substrate according to an exemplary embodiment;

Figure 5 is a cross-sectional view illustrating an exemplary PV module according to an exemplary embodiment;

Figure 6a is a plan view illustrating exemplary installation of a PV module into a vehicle roof according to an exemplary embodiment;

6b, 6c, and 6d are plan views illustrating exemplary geometries of PV modules according to exemplary embodiments;

Figure 6e is a bottom view illustrating an exemplary PV module according to an exemplary embodiment;

Figure 7 is a flow diagram illustrating a PV module process for preparing a top;

Figure 8a is a schematic cross-sectional view showing an assembly with appropriately sized holes prior to lamination, according to an exemplary embodiment;

Figure 8b is a schematic cross-sectional view showing changes to the embodiment of Figure 8a during a lamination cycle in an exemplary implementation;

Figure 9a is a schematic cross-sectional view showing an assembly with improperly sized openings prior to lamination;

Figure 9b is an illustration showing the consequences of improperly sized openings with lamination of Figure 9a;

Figure 10a is a top view showing a PV module with appropriately sized holes according to an exemplary embodiment;

Figure 10b is a top view showing a more generic PV module with appropriately sized holes according to an exemplary embodiment;

Figure 11 is a graph showing aspect ratio and cell thickness in successful and failed laminations for exemplary rectangular apertures;

12 is a flowchart illustrating a process for preparing a PV module with appropriately sized holes for a vehicle, according to an exemplary embodiment.

Detailed Description of Exemplary Embodiments of the Invention

Exemplary embodiments relate to a PV module comprising two glass substrates; a PV layer disposed therebetween; and an adhesive bonding the glass substrates and the PV layer together in an integrated PV module.

PV devices can come in many forms. One area of PV devices is thin film solar cells (TFSCs). For example, TFSC devices include CIGS (Cu(In,Ga)(Se,S) ₂ ) and CIS (CuInSe ₂ ) solar cells.

In order from the front side or light incident side to the rear, CIGS and CIS type photovoltaic devices may include: a front substrate of glass-like material; a front electrode containing a TCO-like transparent conductive layer (e.g., transparent conductive oxide); Absorbing semiconductor film (eg, CIGS and/or CIS film); back electrode; and back substrate of glass-like material. In some cases, an adhesive is provided between the front substrate and the front electrode, and a window layer may also be provided (for example, composed of CdS, ZnO or including the above elements, etc.). Typically light is incident from the front side (or front substrate) of the photovoltaic device through the front electrodes and is absorbed by light absorbing semiconductor films known in the art to generate photovoltaic power.

Layers in a TFSC device can be between a few nanometers and a few micrometers. However, problems may arise when using TFSC in PV installations. First, the materials used in TFSC cells (eg, indium, gallium, cadmium) may be harmful to humans. Further, some TFSC elements may adversely affect the external environment. For example, components in CIGS may degrade when exposed to moisture and may result in reduced lifetime and/or reduced solar cell efficiency. Therefore, there is a need for a method of protecting the TFSC cell from the external environment, and protecting the external environment (eg, a human being) from the TFSC cell.

The detailed description will now be made with reference to the drawings, where like symbols denote like parts. 1 includes a transparent front glass substrate 1, a selective adhesive film 2, a single-layer or multi-layer front conductive electrode 3, an active semiconductor film 5 containing one or more semiconductor layers (such as CIGS, CIS, etc.), a conductive The rear electrode/reflector 10, and the rear glass substrate 11. In different embodiments of the present invention, the light incident surface 5 a of the semiconductor thin film 5 may be textured or not. It is preferred that the back electrode 10 runs continuously or substantially continuously through the entire or substantial portion of the glass substrate 11, and in some cases it may be patterned (eg, striped) according to a desired design. The selective adhesive film 2 may be composed of an adhesive based on an electrically insulating polymer and/or a sealant containing the same, or a material like ethyl vinyl acetate (EVA), polyvinyl butyral (PVB), etc. agent. In an exemplary embodiment, the polymer-based adhesive layer 2 has a refractive index (n) of about 1.8-2.2, more preferably about 1.9-2.1, such as about 2.0, to reinforce the interior when structurally using back glass reflection. Of course, other layers not shown may also be provided in the device. For example, buffering and/or windowing layers may also optionally be provided.

Metals like Mo (molybdenum) can be used as the back electrode (rear contact) 10 of photovoltaic devices such as CIS solar cells. In some cases, Mo can be sputter deposited onto the back glass substrate 11 of sodium or soda lime silicon of the photovoltaic device. Preferably, the back electrode (eg, Mo back electrode) 10 has low stress, high conductivity, and better adhesion to the rear substrate (eg, glass substrate) 11 . In an exemplary embodiment of the present invention, in order to provide this compositional feature, oxygen gas is introduced into the Mo-based back electrode 10 at the initial stage of back electrode deposition on the substrate 11 . The application of oxygen to the Mo-based back electrode 10 can reduce the overall stress of the back electrode and at the same time improve the adhesion of the back electrode 10 to the soda glass or soda lime silica glass substrate 11 . However, in some sputter coaters designed for larger substrates with a width of more than one meter, sometimes It is more difficult to control the oxygen uniformity in the final back electrode film. In the embodiment of FIG. 1 , the Mo-based back electrode (possibly oxidized graded) is supported by the plane of the back substrate 11 . However, in other exemplary embodiments, the back electrode may be formed on the textured surface of the rear substrate 11 .

Figure 2a is a cross-sectional view illustrating the composition of an exemplary PV module according to an exemplary embodiment. A PV module 100 may be provided with a first glass substrate 102 and a second glass substrate 108 disposed on the underside of the PV module 100 (eg, the sun impacts the opposite side of the PV module 100). Additionally, one or more functional PV layers 106 are disposed between the first glass substrate 102 and the second glass substrate 108 . For example, in an exemplary embodiment, functional PV layer 106 may be supported by second substrate 108 . The first substrate 102 and the second substrate 108 may be laminated together using first and second lamination materials 104a, 104b. Thus, the front substrate 1 in FIG. 1 can be the outer substrate 102 in FIG. 2, then the rear glass substrate 11 in FIG. 1 can be the second substrate 108 in FIG. 2, and the selective adhesive layer 2 may be the first laminate 104a in FIG. 4, and the functional PV layer 106 in FIG. 2 may include layers 2, 3, 5, 10 in FIG. However, unlike the exemplary configuration of FIG. 1 , a second laminate material 104b may be provided. In an exemplary embodiment, PV layer 106 may include PV layers (eg, layers 2, 3, 5, and/or 10) disposed (eg, deposited) on a thin film such as a thin stainless steel foil or a conductive polymer coating. Other substrates and/or materials may also be used in other embodiments of the invention.

Figure 2b is a cross-sectional view illustrating the composition of an exemplary PV layer according to an exemplary embodiment. PV layer 106 may include PV material 114 (eg, CIGS) disposed on substrate 112 . For example, the substrate can be stainless steel foil. In an exemplary embodiment, the width of the PV layer 106 may be 1 mm or less, more preferably 0.7 mm or less, and sometimes about 0.5 mm.

The lamination material 104a, 104b may be used to laminate the first and second glass substrates 102, 108 together and encapsulate the PV layer 106. Laminates 104a, 104b may consist of a material like polyvinyl butyral (PVB) or ethyl vinyl acetate (EVA) with a thickness of 0.38-0.76 mm. In an exemplary embodiment, a UV curable polyurethane fluid may also be used as a laminate. This lamination can be accomplished by conventional techniques, eg, heat and/or pressure based lamination techniques, exposure to ultraviolet radiation (eg, UV curable materials), and the like. In an exemplary embodiment, sandwiching the PV layer 106 between the first and second laminates 104a, 104b can make the PV more flexible and/or suitable for insertion into a wide variety of different sizes and/or shapes. Between the inner and outer substrates of the skylight. In other embodiments of the invention, the first and second laminate materials 104a, 104b may be the same or different laminate materials.

The PV layer 106 may comprise a layout of PV cells interconnected by strips of conductive copper tape. In an exemplary embodiment, the PV cells may be single-junction solar cells. Alternatively, the PV unit can also be multiple or series-connected solar cells. The electrical connection of the PV cells can be accomplished by conductive adhesives, solder, others, and the like. Two or more ribbon leads 110 may extend outward from one or more edges of the PV module 100, e.g. cycle battery arrays, drive batteries for hybrid or electric vehicles, etc.). It should be understood that in other exemplary embodiments, there may be one ribbon lead extending from the PV module. In other exemplary embodiments, there may also be two ribbon leads extending from a point along the edge of the PV module.

The thickness of the glass substrates may be 1.5-3.5 mm, however, the thickness, weight, and durability options for the glass substrates 102, 108 and PV module 100 may vary considering the particular application of the PV module. For example, PV modules mounted on sailboats require higher durability than those mounted on car sunroofs (eg, dampening conditions that may occur at sea). In an exemplary embodiment, glass substrate 102 may have a thickness of approximately 2.0 mm, and glass substrate 108 may have a thickness of 1.6 mm.

The two glass substrates 102, 108 may include printed patterns on each major surface. The pattern may frame the PV cells of the PV layer 106 and may visually conceal gaps and connections of the PV layers. For example, the pattern may be formed from sintered ceramic frit, enamel, or other suitable material for application to a glass substrate. For example, a UV curable acrylate or organic substance can be applied to the inner surface of the glass substrate. In an exemplary embodiment, these and/or other materials may be screen printed on desired surfaces in desired locations to form desired patterns.

The two glass substrates 102, 108 can be of various thicknesses and colors. It is preferred to provide a standardized impedance for light travel to the PV layer 106 and a high transmittance type of glass for the glass substrate 102 . High transmittance, low iron glasses may also be used in exemplary embodiments. For example, US Patent Nos. 7,700,870; 7,557,053; 5,030,594, and US Publication Nos. 2006/0169316; 2006/0249199; 2007/0215205; The contents are incorporated herein by reference.

Exemplary soda lime silica glass according to embodiments of the present invention includes, on a weight percent basis, the following basic components:

Table 1: Exemplary base glasses

Other minor ingredients, including various conventional refining aids like SO3, carbon, etc. may also be included in the base glass. In an exemplary embodiment, for example, the glass described herein can be made from a batch _of raw materials silica sand, sodium carbonate, dolomite, limestone, and using sulfates like sodium sulfate ( _Na2SO4 ) and/or Epsom salt (MgSO ₄ x 7H ₂ O) and/or gypsum (any combination about 1:1) are made as refining agents. In an exemplary embodiment, the soda lime silica glass described herein includes, by weight, about 10-15% _Na2O and about 6-12% CaO.

In addition to the base glass (e.g., shown in Table 1), when preparing a glass according to an exemplary embodiment, the glass batch includes a color that renders the glass a neutral color (yellowish in the exemplary embodiment, indicated by a positive b* value). out) and/or materials with high light transmittance (including colorants and/or oxidizing agents). This material can also be raw (eg, a small amount of iron), or added to the base glass material in the batch (eg, antimony and/or the like). In an exemplary embodiment of the invention, the resulting glass may have a visible light transmission of at least 75%, preferably at least 80%, more preferably at least 85%, most preferably 90% (sometimes at least 91%) (Lt D65).

In an exemplary embodiment, in addition to the base glass, the glass and/or glass batch may include or consist of the materials shown in Table 2 below (in weight percent of the total glass composition).

Table 2: Exemplary additional materials in glass

In an exemplary embodiment, antimony may be added to the glass batch in the form of one or more of Sb ₂ O ₃ and/or NaSbO ₃ . Sb(Sb ₂ O ₅ ) may also be used. Antimony oxide as used herein refers to antimony in any oxidation state and is not limited to any particular stoichiometry.

The lower glass redox shows the highly oxidative nature of the glass. Due to antimony (Sb), through antimony trioxide (Sb ₂ O ₃ ), sodium antimonate (NaSbO ₃ ), sodium pyroantimonate (Sb(Sb ₂ O ₅ )), sodium or potassium nitrate and/or sodium sulfate The antimony combination oxidizes and the glass is oxidized to have a lower ferrous content (%FeO). In an exemplary embodiment, the composition of the glass substrate 1 includes, by weight, at least twice as much antimony oxide as the total iron oxide, more preferably at least three times, and most preferably at least four times as much antimony oxide as the total iron oxide antimony.

In an exemplary embodiment, the colored portion is substantially free (except potentially trace amounts) of other colorants. However, it should be understood that some other materials (for example, refining aids, melting aids, colorants and/or impurities) may be present in other embodiments of the present invention without departing from the purpose and/or objectives of the present invention. in the glass. For example, in an exemplary embodiment of the invention, the glass composition is substantially free of erbium oxide, nickel oxide, cobalt oxide, neodymium oxide, chromium oxide, or one, two, three, four, or all of them . "Substantially free" as used herein refers to elements or materials below 2 ppm, and almost as low as 0 ppm.

The total amount of iron present in the glass batch and in the resulting glass, _ie the colored fraction thereof, is expressed as _Fe2O3 according to standard convention. However, it does not mean that all iron is in _{the Fe2O3} form (as above). Also, the amount of iron in the ferrous state (Fe ²⁺ ) described herein is expressed as FeO, although all of the iron in the ferrous state in the glass batch or glass may not be in the form of FeO. As mentioned above, iron in the ferrous state (Fe ²⁺ , FeO) is a blue-green colorant and iron in the ferric state (Fe ³⁺ ) is a yellow-green colorant, but when a neutral or clear color must be achieved Sometimes ferrous blue-green colorants may be less than ideal because stronger colorants will impart a noticeable color to the glass.

As described above, glasses according to exemplary embodiments of the present invention achieve neutral or substantially clear color and/or high transmittance. In an embodiment, the glass produced according to an exemplary embodiment of the present invention has One or more of the following transmitted light characteristics or color characteristics (Lta is % visible light transmission). Here, the a* and b* color values in the table below are determined by each Ill.D65, 10degree Obs.

Table 3: Glass Properties of Exemplary Embodiments

3 is a cross-sectional view illustrating an exemplary PV module after bonding according to an exemplary embodiment. The PV module 200 may include glass substrates 202, 208 with a PV layer 206 disposed therebetween. The PV layer 206 may be smaller in size than the glass substrates 202,208. After PV module 200 is laminated, laminate material 204 may form a seal at the peripheral edges of first glass substrate 202 and second glass substrate 208 . As shown in FIG. 3, the laminate material 204 is only at the edges of the glass substrates 202, 208, however, in other embodiments, the laminate material may be provided along the entire first and/or second substrate 202, 208, For example at least at its peripheral edges. In an exemplary embodiment, laminate material 204 can help isolate the PV layer from the external environment, which can help reduce the likelihood of PV layer degradation (eg, keep the PV cell dry). Additionally, potentially hazardous PV material can be kept within the sunroof away from the outside environment, including occupants in the vehicle cabin. Conductive ribbon leads 210 may extend from PV layer 206 and through laminate 204 . The conductive ribbon lead 210 can be connected to an external energy storage unit (such as a battery) or energy use (such as a fan).

Figure 4a is a cross-sectional view illustrating an exemplary formed glass substrate according to an exemplary embodiment. In an exemplary embodiment, the glass substrates 402, 404 used in the exemplary PV modules may be curved. For example, the sunroof of a car may be slightly curved. Thus, PV modules can replace conventional skylights, being curved in a manner similar to curved skylights.

Apparatus and methods for heating bent glass sheets are known in the art and are described in U.S. Patent Nos. 5,383,990; 6,240,746; 6,321,570; 6,318,125; shown, the entire contents of which are incorporated herein by reference.

Accordingly, the glass substrates 402, 404 can be thermally bent, respectively. Additionally, referring to Figure 4b, a cross-sectional view of an exemplary formed glass substrate is shown in accordance with an exemplary embodiment. The glass substrates 406, 408 can be thermally bent into a unit. This method is economical (eg, one-time thermal bending to complete both glass substrates) and/or helps to provide two glass substrates with substantially similar curvatures.

Figure 5 is a cross-sectional view illustrating an exemplary PV module after a bending process according to an exemplary embodiment. The PV module 500 may include two curved glass substrates 502, 504, and a PV layer 506 sized and formed as desired. As described above, the first and second lamination materials 508 a , 508 b may be used to laminate the first and second substrates 502 , 504 together and encapsulate the PV layer 506 . Once bonded, the PV module 500 may be structurally similar to an existing sheet of glass. Ribbon leads 510 are also configured to facilitate current transfer from PV layer 506 to the exterior of PV module 500 .

FIG. 6 is a plan view illustrating exemplary installation of a PV module into a vehicle roof according to an exemplary embodiment. A PV module 604 may be mounted to the roof 602 of the vehicle 600 . For example, mounting PV modules 604 may replace or be used in place of standard skylights. Electrical leads 606 connected to the PV layers of the PV module 604 can be led out of the PV module. The electrical leads 606 may then be connected to the electronic systems of the vehicle 600 . Optionally, electrical leads 606 may be connected to dedicated equipment such as an exhaust fan.

Generally, when a car is parked in a parking lot on a hot summer day, the temperature inside the car may increase. Generally, a method for preventing temperature rise inside a car is to open windows to evacuate hot air inside the car to the outside. But the disadvantage of this method is that opening the window of the car is less safe than closing the window. Another conventional method is to provide a heat shield over the windshield of the vehicle. However, this method can reduce the heat transfer rate generated, but it is impossible to transfer the generated heat from the interior of the vehicle to the external space.

In an example, PV modules with electrical connections can provide independent power to drive fans, air conditioners, heaters, and the like. Thus, the electrical leads 606 can be connected to an independent high-efficiency air conditioner of the car 600 (eg, independent of the car's electrical system - battery or engine). Alternatively or in addition, electrical leads 606 may be connected to the electronic and electrical systems of vehicle 600 . It facilitates the use of the car's radio, speakers, etc. when the car is not being started and the car's main battery is not being drained.

In other exemplary embodiments, a dedicated backup battery may be provided. Electrical leads from the PV modules can be directly connected to the backup battery. The PV module can help keep the backup battery in a state of charge so that it can be used in emergency situations (eg, when the main battery in a vehicle fails or dies). It should be understood that the PV module may be electrically connected to various other electrical systems inside and outside the vehicle, for example, a drive battery system for a hybrid or electric vehicle.

In operation, a PV module 604 may be installed in the roof 602 of the vehicle 600 in place of a sunroof in a manner similar to uninstalling a sunroof. In an exemplary embodiment, PV module 604 may be substantially similar in size (eg, shape, thickness, etc.) to an unloaded skylight. It can facilitate, for example, the use of PV modules as skylights, whereby the PV modules can be retracted in a skylight-like manner. In an exemplary embodiment, the electrical leads 606 may be modified to provide a continuous connection (eg, so that an electrical connector extends up from the sunroof and/or down from the frame of the vehicle to serve as a kind of electrical connection track). For example, the electrical leads 606 can be extended when the PV module 604 is retracted from the roof (eg, in a manner similar to a sunroof), so that the electrical leads can still be connected even though they are at different locations in the roof. Optionally, the electrical leads may be in contact with an external power source when the PV module is in the closed position. In other words, when the PV module is turned off, the electrical leads can come into contact with the pre-arranged wires. When the PV module is retracted (the sunroof is opened), the electrical leads 606 can be disconnected from the vehicle's electrical systems. In other exemplary embodiments, electrical leads may extend from the PV module at the same location. This embodiment can facilitate the connection of the PV module to external systems (eg, because the interface of the PV module is in one location). It should be understood that other techniques may also be implemented to connect the electrical leads of the PV module to vehicles and/or other external electrical uses.

6b, 6c, and 6d are plan views illustrating exemplary geometries of PV modules according to exemplary embodiments. It should be understood that the lattice patterns shown and described in these figures are examples only and other patterns may be used in other exemplary embodiments of the invention.

PV module 610 is an exemplary 15-string PV assembly. PV module 610 may have an area of 0.32 square meters and have a power output of approximately 30 watts (eg, depending on environmental conditions).

PV module 612 is an exemplary 14-string PV assembly. The PV module 612 may have an area of 0.30 square meters and have a power output of approximately 28 watts (eg, depending on environmental conditions).

PV module 614 is an exemplary 28-string PV assembly. The PV module 614 may have an area of 0.61 square meters and have a power output of approximately 56 watts (eg, depending on environmental conditions). .

Figure 6e is a bottom view illustrating an exemplary PV module according to an exemplary embodiment. The PV module 650 may have a conductive adhesive 652 to create an electrical connection among the solar cells. The conductive adhesive may include an adhesive like silver epoxy, equivalent to silver glue and an adhesive curing agent. This epoxy is available from Applied Technology, for example, designated 100A and 100B.

Conductive adhesive 652 may be attached with conductive tape 654 . Conductive strap 654 may be composed of copper or other conductive material (eg, silver, etc.). Conductive strap 654 may be connected to strap lead 656 . Depending on design requirements, ribbon leads 656 may exit the PV module from one or more edges of the laminate (eg, as shown in FIG. 3 ) at designated locations for grounding.

FIG. 7 is a flow chart illustrating a process for preparing a top PV module. In step 702, a glass substrate for a PV module is provided. As mentioned above, the glass substrates can be of different types and qualities (eg, the first glass substrate can be a high transmittance/low iron type glass). The glass substrate can be processed so that the substrate has the proper perimeter and edge treatment for a particular implementation of the PV module (eg, the design of the glass substrate can depend on its application, eg a skylight). Further, a specific pattern formed using the above-mentioned ceramics may be added.

Then, in step 704, the glass substrate can be thermoformed to conform to the PV module's usage specifications. When the surface shape and/or geometry of the glass substrates meet the specifications for a particular application, in step 706, a PV layer containing PV cells is inserted between the glass substrates.

As described above, thin film solar cells (eg, CIGS or CIS, etc.) may be used in exemplary embodiments. In exemplary embodiments, the glass substrate may be robustly formed (eg, the curvature of the glass substrate may be larger than standard). In this exemplary embodiment, CIGS-like thin film solar cells are preferred. However, it should be understood that other types of solar cell technologies (eg, crystalline silicon solar cells) may also be implemented.

In step 708, a laminate material may be applied to encapsulate the PV layer between the glass substrates. Polyvinyl butyral (PVB) or ethyl vinyl acetate (EVA) or similar materials may be used in exemplary embodiments. In an exemplary embodiment, the PVB may have a thickness in the range of 0.1-1.0 mm, more preferably 0.38 or 0.76 mm. In exemplary embodiments, specific laminate materials may be formulated to provide long-term durability and durable adhesion. Other laminates with similar bond strength, sealing, durability, optical characteristics, and/or other qualities may also be used. For example, in exemplary embodiments, one-part, two-part, or multi-part polyurethanes may be used. Adhesives (eg, pressure sensitive adhesives) may be used in exemplary embodiments. In step 710, after the glass substrate, PV layers, and laminate are bonded (eg, directly facing), the PV module may be heated and pressured. Application of heat and/or pressure promotes bonding of the two glass substrates, sealing the PV layer therein by lamination. Further, in an exemplary embodiment, heat and pressure may render the laminate (eg, PVB) transparent. Certain laminates can of course be processed by other means than heat and pressure, for example, UV curable materials.

When two glass substrates are bonded together with a sandwiched PV layer, it is structurally similar to a single integrated unit (eg, similar to installing a common sunroof into a car). Therefore, in step 712, the newly generated PV module is mounted to the roof of the vehicle. In other words, depending on the size or design of a common skylight, the two glass substrates and the sealed PV array laminated between them are combined into an integrated unit and shaped to scale substantially similar to a common skylight. Here, the process of preparing the PV modules can reduce the cost of the vehicle assembly process. First, vehicle manufacturers may not currently need to modify the body of the vehicle to accommodate a PV-equipped sunroof. Second, in an exemplary embodiment, integrated PV modules (eg, sunroofs with integrated PV arrays) may be provided, and vehicle manufacturers may install pre-packaged PV modules in a manner similar to a conventional sunroof. This approach saves vehicle manufacturers time and money. Additionally, in an exemplary embodiment, the thickness of the sized glass substrate and PV array can be smaller than a typical skylight. Accordingly, installing a PV-equipped sunroof does not reduce the overall headroom available in the vehicle. In an exemplary embodiment, the integrated PV module may have a thickness substantially similar to a normal sunroof, and thus may be retracted to open the sunroof.

As is known in the art, conventional skylights may be encapsulated by an injection molding system using thermoplastics or by a reaction injection molding process using conventional polyurethanes. This technology facilitates the sealing and installation of glass skylights. Likewise, integrated PV modules (eg, PV module 200 ) can also be packaged using similar or identical techniques. Accordingly, for example, a PV module 200 encapsulated by this technique can directly replace an existing vehicle roof system. Additionally, packaging facilitates routing of conductors and connectors for PV functions (eg, electrical leads, etc.).

It should be understood that in different embodiments of the invention, the steps shown in FIG. 7 may be performed in a different order and/or some steps may not be performed. For example, a laminate can be provided to a glass substrate, and then the PV cell sandwiched between the laminate and the glass substrate.

Certain PV modules used in certain vehicles (eg, automobiles) may need to comply with common use standards. It should be understood that the techniques described herein can provide that meets and/or exceeds the requirements for AS-3 laminates. For example, the following tests may be passed in an exemplary embodiment: 1) 30 ft. drop dart impact test; 2) 30 ft. pellet impact test; 3) 2 hour boil test; and 4) two week water mist exposure. Additionally, other exemplary embodiments meet or pass other non-required tests, for example, 1) two weeks salt spray exposure; 2) 1000 hours 85 degree/85% RH exposure; 3) shear resistance of PV solar cells in PV modules test; and 4) copper busbar shear test. Accordingly, exemplary embodiments may meet and/or exceed certain tests (eg, safety, durability, etc.).

While the exemplary embodiments are described using hot bending, in other exemplary embodiments, cold bending may alternatively, or in addition, be used to form the glass substrate.

While the exemplary embodiments are described using TFSCs, other types of solar cells may be used in other exemplary embodiments. For example, crystalline silicon (c-Si) can be used with the techniques described above. Amorphous silicon (eg, a-Si), microcrystalline silicon, and/or other materials may be used in other exemplary embodiments.

In different embodiments, the glass substrates can have the same or different compositions. For example, in an exemplary embodiment, a low-iron substrate may be provided for the outermost substrate, and a relatively less expensive type of material may be provided for the inner substrate. It provides the necessary strength and thickness while allowing more potential light access to the PV layer. The configuration of low transmittance glass on the inner substrate on the side of the PV layer facing away from the sun will not affect the overall performance of the module.

Those skilled in the art will appreciate that the use of glass substrates with different compositions may result in glass substrates having different heating coefficients. For example, a first glass substrate may have a relatively lower iron percentage when compared to a second glass substrate. Since the second glass substrate can have a higher iron count, it can heat up more rapidly than the first glass substrate (eg, because iron absorbs more heat). Accordingly, the thermal expansion rates of the first and second glass substrates may be different. It should be understood that when the thermal expansion rates of the two laminate materials are different, lamination cannot be maintained because the two materials expand and contract at different rates. Therefore, the heating properties of the two laminates need to be correctly identified. For example, differences in CTE are important when using infrared (IR) heating and/or exposure to IR. Different iron content means different IR absorption.

One approach for solving this problem is to adjust the heat on either or both materials. For example, under "normal" conditions, when the first glass substrate heats more slowly than the second glass substrate, adding heat to the first glass substrate or removing heat from the second glass substrate (e.g. , through the heat sink). Thus, in an exemplary embodiment, a first (eg, low iron) substrate may be preferentially heated over a difference in heating coefficient from a second substrate. In exemplary embodiments, the heating properties of the assembly can be enhanced and optimized, for example, to ensure that one substrate is properly laminated to another. Exemplary heating properties may be to account for different glass compositions, etc. It is also possible to adjust the composition of the laminate and/or select a particular laminate, for example to account for the above-mentioned differences.

Depending on the heating properties taking into account the different compositions of the first and second substrates, the laminating step may include heating the first and second substrates. Similarly, the first and second substrates may be thermally bent (eg, together or separately) depending on the heating properties that take into account the different compositions of the first and second substrates.

One disadvantage of incorporating solar cells into a sunroof of a vehicle is that, for example, the solar cells are not transparent. Of course, complete transparency cannot be expected since excessive heat from the full sun can overheat the passengers and/or the interior of the vehicle. However, allowing some light to be delivered into the vehicle is balanced by harvesting the sun's energy to enhance the vehicle's electrical generation system. Since most solar cells are not transparent or on a transparent substrate, an alternate technology is needed to allow a predetermined amount of light to pass through the PV sunroof and into the vehicle interior.

The inventors of the present application recognized the necessity of this balance and accordingly investigated the possibility that making multiple vias in the solar cell would allow a small fraction of the incident light to enter the cabin. (While other commercial articles have higher or lower visible light transmittance, eg, different vehicles, different car models, etc.), some commercial sunroofs have a visible light transmittance of about 10%. Therefore, when providing PV functionality, it is sometimes necessary to match the percent transmission.

However, while theoretically at least increasing the transmittance by a series of regular through-holes and being fairly easy to manufacture, the inventors have found that this method entails sandwiching the solar cell between two adhesive layers, in turn bonded to the glass sheet The interior and exterior of the glass to prepare the laminated structure. In particular, the inventors have discovered that during lamination, a solar cell or assembly of solar cells with small holes causes the adhesive to flow into the holes and create a non-scattering light path through the filled holes. So the vias actually cause more problems than they solve, even if the vias are not filled to allow light to pass through, they can still generate an irregular appearance e.g. When viewed from the passenger's point of view.

Here, it has been unexpectedly found that, in view of the above and in the exemplary implementation, it is not necessary to change the lamination process considering PV sunroof lamination as well as other non-sunroof glass laminations (windshields, etc.). That said, it has been found herein that, in view of the foregoing and in the exemplary implementation, it is not necessary to tailor the bond type and temperature, pressure, cycle for PV sunroof laminations compared to other non-sunroof glass laminations (windshield, etc.) , and other related processing conditions.

Instead, it was found here that a subset of pore sizes, aspect ratios, and spacings have a unique optimum that satisfies the conditions for adhesive to flow into the pores so that the adhesive fills or nearly fills the openings, thereby non-scattering Light passes through the opening and into the cabin and has a more uniform (more aesthetically pleasing) appearance when viewed from the perspective of the occupants in the vehicle.

Thus, a customer request to make regular openings in the PV cells on laminated louvers led to the discovery that only some openings in the PV structure allowed the lamination to be substantially free of entrapped air bubbles (usually air, but sometimes other gases). Thus, exemplary embodiments of the present invention take into account hole geometry to reduce air entrapment that may occur during fabrication.

Figure 8a is a schematic cross-sectional view showing an assembly with appropriately sized holes prior to lamination, according to an exemplary embodiment. It should be understood that Figure 8a and Figures 8b, 9a, 9b are not shown to scale. For example, glass substrates are typically thicker than adhesives and solar cells. Also, the pores may be smaller than the thickness of the glass, and/or may be regular or irregular in shape. In an exemplary embodiment, the holes may have one major dimension that is greater than the other major dimension. For example, the hole may be a groove, which may be 1 mm or smaller on the short side and 1 mm or longer on the long side.

As shown in Figure 8a, the solar cell stack 80 is sandwiched between first and second substrates 804a, 804b. Adhesive material 806 is disposed on one or both sides of solar cell stack 802 . A hole 808 is formed in the solar cell stack 802 to increase visible light transmission into the vehicle (eg, compared to a situation where no hole is provided). It will be appreciated that although one aperture is shown in Figure 8a, multiple apertures may be provided in a regular or irregular arrangement.

Figure 8b is a schematic cross-sectional view showing changes to the embodiment of Figure 8a during a lamination cycle in an exemplary implementation. Figure 8b shows that during the lamination cycle, the adhesive will stick to the glass, conforming to its plane, and to the solar cell, conforming to its plane. By judicious selection of the size of the holes, the adhesive will also relax and completely or substantially completely fill the openings of the holes. The light passes through the adhesive, preferably without seeing any air-adhesive interface and/or any deformed surfaces (eg, associated with air bubbles due to trapped gas, etc.).

Figure 9a is a schematic cross-sectional view showing an assembly with an improperly sized opening 808' prior to lamination. Figure 9b is an example diagram showing the consequences of improperly sized openings with lamination of Figure 9a. As shown in the example of FIG. 9b, adhesive 806 is not completely or substantially filled into opening 808'. Air pockets 902 are instead formed along the air-adhesive interfaces 904a, 904b. Depending on the situation, the shapes of the interfaces 904a and 904b may be smooth or irregular, and may sometimes partially touch each other. It should be understood that incident light on these features may be highly scattered or bent, resulting in ineffective transmission of light through openings in solar cell stack 802 . The result may be a less than ideal appearance and/or not meeting the target visible transmittance.

Figure 10a is a top view showing a PV module with appropriately sized holes according to an exemplary embodiment. The dimensions shown in Fig. 10a are in mm, but it is understood that other embodiments of the invention may also be suitable for other dimensions. The openings shown in the example of Fig. 10a have a regular shape and have regular spacing. However, it should be understood that this is not required in all exemplary embodiments. For example, in different exemplary embodiments, openings of different sizes may be formed at one or more regular or irregular intervals. The vertical dimension in Figure 10a shows the centerline of the opening.

As shown in the example of Figure 10a, the PV module includes two differently sized regions 1002a, 1002b for supporting a stack of solar cells. The regions 1002a, 1002b are at least partially defined by conductive lines 1004, and bus bars 1006. It should be understood that the conductive wires 1004 and/or the bus bars 1006 may comprise silver or any other conductive material. In the example of Fig. 10a, bus bar 1006 may protrude downwardly from the body portion of the PV module and may represent the positive terminal of the circuit in an exemplary embodiment. Although not shown in the example of Fig. 10a, an additional bus bar could protrude upwards from the opposite side of the module and form the negative terminal of the circuit. In some cases, such as the bus bars 1006 shown in Figure 10a, the bus bars may be substantially straight, eg, to reduce the visual or aesthetic impact of the bus bars, allowing a larger area to be covered by the solar cell functional layer. In an exemplary embodiment, the bus bars may collectively serve as "collection lines". However, it should be understood that other designs could be used to harvest energy in other ways, and thus the use of the busbars shown in Figure 10a may not be required.

In the Figure 10a example, openings are configured in all other rows of the grid. Two openings 1008a, 1008b are arranged in the larger area 1002a, and only one opening 1008c is arranged in the smaller area 1002b. Each opening 1008 has the same size and shape. As noted above, opening 1008 may be sized and shaped to meet a target visible transmittance. In the exemplary embodiment of Fig. 10a, the opening is in the shape of a slot with rounded corners. The outer diameter of the groove is 23 mm and the inner diameter is 1 mm. Thus, the opening is approximately 23 square millimeters in area. However, the opening 1008 may be further controlled (eg, collection lines, grid, etc.) corresponding to a minimum distance between the edge of the opening and the conductive material. It has been found here, for example, that an edge-to-edge distance of about 1 mm is sufficient to prevent short circuits which could render the module partially or completely inoperable. A distance of about 2 mm is preferred, and a distance of about 3 mm is more preferred.

In an exemplary embodiment, the openings may be grouped between grid lines in the height dimension. For smaller areas 1002b, the openings 1008c may be centered horizontally between the edge of the module and the adjacent busbar 1006. For larger regions 1002a, opposite edges of the openings 1008a, 1008b may be spaced equidistantly from their adjacent generatrices 1006, respectively.

As mentioned above, Figure 10a is illustrated in several ways. Figure 10b is a top view showing a more generic PV module with appropriately sized holes according to an exemplary embodiment. Bus bars are removed as shown and typical or example dimensions are provided. Of course, it should be understood that these dimensions may be altered in different exemplary embodiments. Similarly, differently shaped openings may be provided in one or more different embodiments. In particular, as shown in Figure 10b, the major distance of the opening is 30 mm and the minor distance of the opening is 1 mm. Openings in the periphery are spaced 2.3mm from the edge, for example, to enable multiple modules to be coupled to each other and/or to a vehicle or the like. Adjacent openings are spaced 5mm apart from each other, so that there is enough space for bus bars or other major electrical connections to reduce the possibility of short circuits.

Figure 11 is a graph showing aspect ratio and cell thickness in successful and failed laminations for exemplary rectangular holes. Figure 11 is a graph showing the length-to-width ratio (in common units) of an exemplary rectangular aperture compared to cell thickness (eg, mils). The area above the line in Figure 11 illustrates the length-width geometry of the unfilled laminate (ie, representing failure), and the area below the line illustrates the length-width geometry of the filled laminate. Different curves, such as that shown in FIG. 11 , can be developed into different types of geometrically shaped holes (e.g., square, rectangular, oval, hexagonal, and/or other shaped holes), laminated materials, high pressure Or heat treatment cycle and processing conditions (such as temperature, pressure, cycle, etc.) and so on. The value of the boundary curve can be determined empirically or calculated theoretically based on the selected material. In different cases, borderlines may be curved or substantially straight.

12 is a flowchart illustrating a process for preparing a PV module with appropriately sized holes for a vehicle, according to an exemplary embodiment. As shown in FIG. 12, in step S1102, the geometry of the holes suitable for the target visible transmittance and for the flow of the adhesive material therein is determined. As described above, the size, aspect ratio, and spacing of the holes may be considered to meet the conditions for adhesive flow into the holes, eg, specific adhesive material, PV module thickness, etc. In step S1104, one or more holes may be formed in the PV module, for example according to a selected hole geometry. Holes may be formed by any suitable technique. For example, by laser scribing (e.g., using equipment sold by Hitachi through American Mechanics, which is modified to suit needs and set the size, location, layout, etc., or any other supplier), cutting, perforating, and/or Any other suitable technique to form the holes. A glass substrate is provided in step S1106. As mentioned above, the substrate can be bent. In step S1108, the glass substrate and the PV module in which the holes are formed are laminated together. As part of this process, bonding material flows into the pores. Preferably, upon lamination, the pores are filled or substantially filled such that there are no significant spacing and/or no further interfaces in the region near the pores. Furthermore, with lamination, the assembly is substantially free of air bubbles and the like. In step S1110, the PV assembly is finally provided for installation (eg, as a sunroof in a vehicle).

In view of the above, it should be appreciated that the exemplary embodiments relate to a PV module comprising one or more openings. In some cases, the characteristics of the opening may be selected and/or adjusted to allow transmitted light into the interior compartment of the vehicle while still maintaining a more aesthetic appearance for the components making up the PV module. In addition, exemplary embodiments consider constraints and select configurations related to the nature of the adhesive and lamination process (including processing conditions, such as temperature, pressure, cycle time, etc.) to ensure that the desired amount of light passing through the aperture is successfully ground transmission. For example, the selected opening size can be adjusted to allow the desired adhesive material to flow properly into the opening. Exemplary embodiments relate to the shape and size of the subset of openings such that the cross-section of the laminated adhesive is substantially uniform, eg, a particular adhesive material and a set of processing conditions.

For example, assume 10% of the overall light transmittance of incident light passing through an opening for a connection configuration including a specific adhesive and lamination cycle as well as a specific solar cell thickness, it will be understood that when having a higher When the ratio of the length to width of the hole is a rectangular opening (which can also be assumed to be circular), the laminate will not penetrate successfully. Conversely, a ratio below this value allows successful passage through the opening. In an exemplary embodiment, the presence of a boundary is identified and, as a corollary, an area is defined by the boundary, enabling successful opening filling, and this information is then used to construct a PV assembly for the vehicle.

In exemplary embodiments, one or both substrates may be heat treated (eg, heat tempered or heat strengthened). As used herein, "thermal treatment" and "thermal treatment" mean heating a substance to a temperature sufficient to effect thermal tempering and/or thermal strengthening of the glass containing the substance. This definition includes, for example, heating the coating material in an oven or furnace at a temperature of at least 550 degrees Celsius, preferably at least 580 degrees Celsius, more preferably at least 600 degrees Celsius, even more preferably at least 620 degrees Celsius, most preferably at least 650 degrees Celsius , and allow sufficient time for thermal tempering and/or thermal strengthening, which may be two minutes to ten minutes in an exemplary embodiment.

As used herein, the terms "on," "supported by," etc. should not be construed to mean that two elements are directly adjacent to each other unless expressly stated otherwise. In other words, a first layer may be expressed on or supported by a second layer even if there are one or more layers between the first layer and the second layer.

In an exemplary embodiment, a method of making an integrated photovoltaic PV module for a vehicle is provided. providing first and second glass substrates; providing a PV module having a plurality of through holes formed therein; laminating the first and second glass substrates with the PV module therein . Wherein, during said lamination, due to the size, shape, and layout of said vias, lamination material is filled into at least said plurality of vias in said PV module. The through-holes collectively have a selected total area to achieve at least a selected target value of visible light transmission through the integrated PV module.

In addition to the features of the preceding paragraph, in an exemplary embodiment, the target value may be 10%.

In addition to the features of any of the preceding two paragraphs, in exemplary embodiments, the PV module may include a plurality of spaced apart solar cells.

In addition to the features of the preceding paragraph, in exemplary embodiments, the solar cells may be separated by a grid of conductive material.

In addition to the features of the preceding paragraph, in an exemplary embodiment, the vias are spaced apart by a gridline distance sufficient to prevent electrical shorting.

In addition to the features of the preceding paragraph, in an exemplary embodiment said distance may be at least 1 mm.

In addition to the features of any of the preceding four paragraphs, in exemplary embodiments, the through-holes may be located substantially in the center of the cells of the grid.

In addition to the features of any of the preceding five paragraphs, in exemplary embodiments at least some of the vias may be located between adjacent solar cells.

In addition to the features of any of the preceding six paragraphs, in exemplary embodiments at least some of the vias may be located at a peripheral edge of the PV module closer to the peripheral edge than any solar cells.

In addition to the features of any of the preceding eight paragraphs, in exemplary embodiments, multiple bus bars (eg, 3 positive and 3 negative, or other suitable configurations) may be connected to the PV module.

In addition to the features of any of the preceding ten paragraphs, in an exemplary embodiment, the through holes are respectively extended and have rounded corners.

Exemplary embodiments relate to a method of making a vehicle, the method comprising: providing an integrated photovoltaic PV module prepared by the method of any one of the preceding eleven paragraphs; and mounting the integrated PV module to the in the vehicle.

In an exemplary embodiment, a method of making a photovoltaic PV module is provided. A substrate is provided on which a plurality of solar cells are formed; a grid-shaped conductive material is arranged on the substrate; a plurality of through holes are formed in the substrate, and the pattern thereof is (a) the through holes have selected a certain total area so that the visible light transmittance through the integrated PV module reaches the target value for which the PV module is set, and (b) the through-holes have an aspect ratio and positioning sufficient to make the integrated PV module The laminate material used flows into it and fills the through holes.

In addition to the features of the preceding paragraph, in an exemplary embodiment, the through holes may be formed by laser cutting.

In addition to the features of any of the preceding two paragraphs, in an exemplary embodiment, the solar cells of the PV module may be CIGS type solar cells.

In an exemplary embodiment, there is provided an integrated photovoltaic PV module for a vehicle comprising: first and second glass substrates; a PV module comprising a plurality of spaced solar cells and having a plurality of solar cells formed therein through holes, the PV module being inserted between the first and second glass substrates; and a plurality of polywires formed on the substrate between adjacent solar cells. Wherein the PV module is laminated to the first and second substrates, lamination material is filled into the plurality of vias in the PV module due to the size, shape, and layout of the vias. hole. Wherein, the through holes collectively have a selected total area, so that the visible light transmittance through the integrated PV module reaches a selected target value.

In addition to the features of the preceding paragraph, in an exemplary embodiment, the vias are spaced apart by a gridline distance sufficient to prevent electrical shorting.

In addition to the features of any of the preceding two paragraphs, in an exemplary embodiment, the through-holes may be located substantially in the center of the cells of the grid.

In addition to the features of any of the preceding three paragraphs, in an exemplary embodiment,

A first subset of the vias are located between adjacent solar cells and a second subset of the vias are located at a peripheral edge of the PV module closer to the peripheral edge than any solar cells.

In addition to the features of any of the preceding three paragraphs, in an exemplary embodiment, the laminate may be PVB.

In addition to the features of any of the preceding four paragraphs, in an exemplary embodiment, the solar cell may be a CIGS type solar cell.

In addition to the features of any of the preceding six paragraphs, in an exemplary embodiment, the second glass substrate has more iron than the first glass substrate.

Exemplary embodiments relate to a skylight comprising an integrated photovoltaic PV module as described in any of the preceding seven paragraphs.

As mentioned above, although the present invention has been described with reference to the most practical and preferred embodiments, the present invention is not limited to the described embodiments, but various modifications and variations can be made within the scope of the above description, which will be explained later. The scope of the appended claims is defined.

Claims (23)

1. A method of preparing an integrated photovoltaic PV module for a vehicle, the method comprising: providing first and second glass substrates; providing a PV module having a plurality of through holes formed therein; laminating said first and second glass substrates with said PV module therein, and wherein, during said lamination, lamination material is filled into at least said plurality of through-holes in said PV module due to the size, shape, and layout of said through-holes, and Wherein the through-holes collectively have a selected total area such that the visible light transmittance through the integrated PV module reaches at least a selected target value. 2. The method of claim 1, wherein the target value is 10%. 3. The method of any one of the preceding claims, wherein the PV module comprises a plurality of spaced apart solar cells. 4. The method of claim 3, wherein the solar cells are separated by a grid of conductive material. 5. The method of claim 3, wherein the vias are spaced apart by a gridline distance sufficient to prevent electrical shorts. 6. The method of claim 5, wherein the distance is at least 1 mm. 7. The method of any one of claims 4-6, wherein the through-holes are located at the cell centers of the grid. 8. A method as claimed in any one of the preceding claims, wherein at least some of the vias are located between adjacent solar cells. 9. The method of any one of the preceding claims, wherein at least some of the through holes are located at a peripheral edge of the PV module and are closer to the peripheral edge than any solar cells. 10. The method of any one of the preceding claims, further comprising connecting a plurality of bus bars to the PV modules. 11. A method as claimed in any one of the preceding claims, wherein the through-holes are respectively extended and have rounded corners. 12. A method of making a vehicle, the method comprising: providing an integrated photovoltaic PV module prepared by the method of any one of the preceding claims; and Installing the integrated PV module into the vehicle. 13. A method of making a photovoltaic PV module, the method comprising: providing a substrate having a plurality of solar cells formed thereon; disposing a grid-shaped conductive material on the substrate; A plurality of through-holes are formed in the substrate in a pattern such that (a) the through-holes collectively have a total area selected such that visible light transmission through the integrated PV module achieves a target for which the PV module is designed and (b) the vias have an aspect ratio and positioning sufficient to allow the laminate material used in making the integrated PV module to flow therein and fill the vias. 14. The method of claim 13, wherein the via holes are formed by laser cutting. 15. The method of claims 13-14, wherein the solar cells of the PV module are CIGS type solar cells. 16. An integrated photovoltaic PV module for a vehicle, comprising: first and second glass substrates; a PV module comprising a plurality of spaced-apart solar cells and having a plurality of vias formed therein, the PV module being interposed between the first and second glass substrates; and a plurality of polywires formed on the substrate between adjacent solar cells, Wherein the PV module is laminated to the first and second substrates, lamination material is filled into the plurality of vias in the PV module due to the size, shape, and layout of the vias. hole, and Wherein, the through holes collectively have a selected total area, so that the visible light transmittance through the integrated PV module reaches a selected target value. 17. The module of claim 16, wherein the vias are separated by grid lines at a distance sufficient to prevent electrical shorting. 18. The module of claim 17, wherein the through hole is located at a cell center of the grid. 19. The module of any one of claims 16-18, wherein a first subset of said vias are located between adjacent solar cells, and A second subset of the through-holes is located at a peripheral edge of the PV module and is closer to the peripheral edge than any solar cells. 20. The module of any one of claims 16-19, wherein the laminate material is PVB. 21. The module of any one of claims 16-20, wherein the solar cells are CIGS type solar cells. 22. The module of any one of claims 16-21, wherein the second glass substrate has more iron than the first glass substrate. 23. A skylight comprising the integrated photovoltaic PV module of any one of claims 16-22.