Camouflaged solar panels with obscuring color matching

Abstract

The patent discloses a solar panel, characterized in comprising: a top plate; a polymer front plate; a photovoltaic cell layer adjacent to the polymer front plate, the photovoltaic cell layer comprising a plurality of photovoltaic cells encapsulated in a photovoltaic cell layer material; and a textured back plate. In addition, the patent also discloses a solar panel, characterized in comprising: a plurality of photovoltaic cells encapsulated in a photovoltaic layer material, the plurality of photovoltaic cells comprising a first topography; a top plate disposed on a first side of the photovoltaic layer; and a textured layer comprising a second topography that matches the first topography, wherein the textured layer reflects light that matches a color of the plurality of photovoltaic cells, and the textured layer is disposed on a second side of the photovoltaic layer opposite the first side.

Description

Technical Field

[0001] This invention relates to solar panels; more specifically to techniques for shading solar panels from certain lines of sight or advantageous positions, color matching the backsheet of the solar panel with the cells of the panel, and camouflaging solar panels. Background Technology

[0002] Currently, most of the electricity generated for lighting and heating in homes and buildings comes from coal, oil, hydroelectric dams, nuclear power, wind power, and ocean current power. Electricity is generated by utility companies at power plants and delivered to end users via transmission and distribution lines. Electricity is distributed to residential and commercial facilities at available voltage.

[0003] Most technologies currently used for generating electricity have fuel costs. All facilities used to generate electricity have facility costs. Furthermore, transmission and distribution lines are expensive. Power losses during the transmission of electricity from power plants to end users can be substantial. As electricity consumption continues to increase, additional facilities must be built to meet the rising demand.

[0004] Fossil fuels such as oil and coal, which generate most of the electricity, are non-renewable. The prices of these natural resources continue to rise. In the case of hydropower, the available electricity output is entirely dependent on natural conditions, such as rainfall. For example, during years with low rainfall, power generation is also low, affecting all groups using this power source. Wind energy is typically only available during the day and fluctuates seasonally and based on local climate conditions. In the case of nuclear power, the technology is expensive, power plants are costly to build, and despite extensive safeguards, nuclear hazards cannot be completely eliminated. Nuclear power generation is not used in many parts of the world for safety reasons.

[0005] Furthermore, the adverse environmental impacts of all these power generation methods are enormous. In other words, each of these methods has its own adverse environmental impacts. For example, hydroelectric dams negatively impact biodiversity and could trigger devastating floods if they fail. Wind power generation occupies vast amounts of land and can be aesthetically unappealing. In the long run, coal and oil power generation contributes to environmental degradation through carbon dioxide and toxic emissions, severely impacting natural climate cycles and harming all life on Earth. Similarly, nuclear waste can be harmful; its disposal is extremely expensive and also has the potential to have adverse environmental impacts.

[0006] Solar panels, also known as photovoltaic (PV) panels, typically consist of a relatively large number of photovoltaic cells to directly convert solar energy into electrical energy. This electricity is used to replace electricity generated from other sources and to power residential and commercial facilities. Solar panels are usually arranged in arrays and electrically connected together to produce a combined electrical output. Solar arrays are typically connected to battery banks and then to the power grid via inverters. Excess electricity generated by a series of solar panels is fed back into the public grid and transmitted to other users. Attached Figure Description

[0007] Figure 1 It is a diagram showing the relationship between solar panels installed on the sloping roof of a house, a walking observer, and the sun.

[0008] Figure 2 This is a diagram showing various angles of a solar panel array with different orientations relative to a horizontal reference line.

[0009] Figure 3 This is an exploded view of a solar panel constructed according to one or more embodiments.

[0010] Figure 4 This is a diagram of louvers for a solar panel constructed according to one or more embodiments.

[0011] Figure 5A This is a diagram illustrating the path through which sunlight is irradiated onto a solar panel via a louver layer according to one or more embodiments.

[0012] Figure 5B This is a diagram illustrating a solar panel including tilted louvers constructed according to one or more embodiments.

[0013] Figure 6A It is a graph showing the street visibility index relative to the roof angle of the solar panels constructed according to one or more embodiments.

[0014] Figure 6B It is a graph showing the percentage of sunlight transmitted through the blinds relative to the solar panel angle of a solar panel constructed according to one or more embodiments.

[0015] Figure 7A , 7B 7C and 7D are graphs showing the percentage of sunlight transmitted through the blinds relative to the solar panel angle of a solar panel constructed according to one or more embodiments.

[0016] Figure 8A and 8B A prior art solar panel and a portion thereof constructed according to one or more embodiments are shown.

[0017] Figure 9A and 9B A prior art solar panel and a portion thereof constructed according to one or more embodiments are shown.

[0018] Figure 10A and 10B It is a photograph of a roof tile in which solar panels constructed according to one or more embodiments are installed.

[0019] Figure 11A and 11B Includes photographs and figures illustrating steps for designing solar panels for one or more residences according to one or more embodiments.

[0020] Figure 12 This is an aerial view of a residential area where homes are equipped with household solar panels designed according to one or more embodiments.

[0021] Figure 13 It is a photograph showing a view of a dwelling with solar panels designed and constructed according to one or more embodiments installed on it.

[0022] Figure 14 It is a photograph showing a view of a dwelling with solar panels designed and constructed according to one or more embodiments installed on it.

[0023] Figure 15A , 15B Figures 15C and 15D show a top layer made of glass, which includes a jagged surface that shields the covered photovoltaic cells from a low angle.

[0024] Figure 16 This is a cross-sectional side view showing a laminated solar panel constructed according to one or more embodiments.

[0025] Figure 17 This is a cross-sectional side view showing a coated backplate constructed according to one or more embodiments.

[0026] Figure 18 It is a graph showing the reflectance spectrum of a solar panel constructed according to one or more embodiments.

[0027] Figure 19 This is a cross-sectional side view showing a laminated solar panel constructed according to one or more embodiments.

[0028] Figures 20A-20B It is a random pattern generated according to one or more embodiments that can be used to generate a camouflage film.

[0029] Figure 21AIt is a solar tile including a camouflage film according to one or more embodiments.

[0030] Figure 21B It is a solar tile without a camouflage film according to one or more embodiments.

[0031] Figures 22A-22D It is a solar tile with a camouflage film according to one or more embodiments.

[0032] Figure 23 These are a series of microscopic photographs showing the morphology of silicon wafers.

[0033] Figure 24 This is a cross-sectional side view showing a laminated backing according to one or more embodiments. Detailed Implementation

[0034] There are various design trade-offs for solar panels. Due to their array installation, solar panels offer advantages such as high efficiency, low cost, and aesthetics. However, these solar panel arrays may be perceived as glaring by some observers. For example, residential solar arrays are typically installed on the roofs of houses and other buildings. When installed on a house roof, the solar panels are mounted parallel to the roof. While this installation technique is cost-effective, the photovoltaic cells of the solar panels are visible to those observing the house or other structures, resulting in an unsightly appearance and reducing the aesthetic appeal of the residence. Such an unsightly appearance may also violate restrictive covenants in certain residential areas. Therefore, it is desirable for solar panels to have an appearance similar to or the same color as the roofing material. Furthermore, it is desirable for solar panels to have a uniform perceived color and be visually appealing within their area. The following disclosures provide various techniques for improving the aesthetics and performance of solar panels.

[0035] 1. Shielding the solar cell array from certain viewing angles

[0036] Figure 1 This diagram illustrates the relationship between a solar panel 102 (or solar panel array) installed on a sloping roof of a residence, a walking observer, and the sun. As shown and as is generally known, it is desirable to position the solar panel 102 perpendicular to the angle of incidence of sunlight from the sun to maximize the capture of solar energy and its conversion into electricity. A walking observer of the solar array 102 may find the solar panel 102 unsightly. Furthermore, the visibility of the solar panel 102 may violate restrictive covenants or detract from the aesthetic character of the residence or other structure on which the solar panel 102 is mounted.

[0037] Therefore, according to some embodiments, the solar panel 102 has a structure that helps to shade the solar panel 102 from being observed by a walking observer. In the structure of the solar panel 102, the solar panel 102 includes one or more louver layers. Such a solar panel structure will be described below with reference to the appendix. Figure 3 Further description. When viewed from a lateral angle, for example... Figure 1 When viewed from a side angle by a walking observer, the louvered layer of the solar panel gives the solar panel a substantially or completely pure color. In other words, the louvered layer helps to shade the solar panel or solar cell so that it is not visible along certain lines of sight. The louvered layer optionally includes a film containing louvers.

[0038] Figure 2 This is a diagram showing various angles of an array of solar panels at different orientation angles relative to a horizontal reference line. Each of solar panels 202, 204, and 206 is relative to... Figure 2 The solar panels are installed at different angles for the sun and for a walking observer. According to some embodiments, the louvers of solar panels 202, 204, and 206 are designed and constructed based on the installation angles of solar panels 202, 204, and 206. Examples of the design and construction process for solar panels 202, 204, and 206 will be further described below with reference to the following figures.

[0039] Figure 3 This is an exploded view of a solar panel 300 constructed according to some embodiments. The solar panel 300 includes a backsheet layer 302, a bottom encapsulation layer 304 adjacent to the backsheet layer 302, a plurality of photovoltaic cells 306 adjacent to the bottom encapsulation layer 304, a top encapsulation layer 308 adjacent to the plurality of photovoltaic cells 306 and wherein a plurality of louvers are constructed to block lateral viewing of the plurality of photovoltaic cells 306, and a top layer 310 adjacent to the top encapsulation layer 308.

[0040] In some embodiments, the backsheet layer 302 is made of glass or a barrier film. The bottom encapsulation layer 304 may be made of ethylene-vinyl acetate (EVA), a copolymer of ethylene and vinyl acetate, also known as poly(ethylene-vinyl acetate) (PEVA). The photovoltaic cell 306 may have a conventional construction. In some embodiments, the top encapsulation layer 308 is a molded structure of EVA including louvers. The top layer 310 may be made of textured, toughened glass with a low iron content and sufficient thickness to protect the bottom component of the solar panel 300. The encapsulation layer may also be a polyolefin sealant such as 3M Solar Sealing Film P08100N.

[0041] The top encapsulation layer 308 may include a plurality of louvers distributed within its area. These plurality of louvers may include different angles of incidence across the top encapsulation layer 308. Furthermore, in some embodiments, a first group of the plurality of louvers has a first angle of incidence, and a second group of the plurality of louvers has multiple louvers with different angles of incidence. In other configurations, the louvers have multiple different angles of incidence. As will be further described herein, the louvers are designed to provide visual obstruction of the photovoltaic cell 306 when viewed from a side angle, but to minimize solar energy obstruction to the photovoltaic cell 306.

[0042] Multiple louvers can have a designed color that, when viewed from a side angle, gives the solar panel the appearance of that color, thus blocking its view. Furthermore, this configuration allows the solar panel to have a designed color when viewed from a side angle and a different color when viewed from angles other than the side angle.

[0043] For the embodiments of the solar panel described herein, it is desirable to increase the angular transparency of the blinds to improve solar efficiency, while giving the solar panel a solid-color appearance when viewed from a side angle. A variety of colors can be used, including shades of gray from dark to light, earthy tones, cedar colors or finishes, and printed finishes. Therefore, the top encapsulation layer 308 including the blinds can be configured to not only produce a specific color or color appearance seen from a side viewing angle, but also to produce a specific pattern or design.

[0044] According to some aspects disclosed in this invention, the solar panel 300 may include small vertical walls to further shade the photovoltaic cells 306 when viewed from the side. Furthermore, the top layer 310 may have a textured surface (textured glass), for example, a serrated pattern. This serrated surface may include vertical walls on each tooth that assist in blocking the view of the covered photovoltaic panel from a low viewing angle. Examples of this structure are shown in... Figures 15A-15D As further illustrated, the solar panel 300 may also include electronic devices or electrical connectors for connecting the solar panel 300 to other solar panels or other electrical connections.

[0045] Figure 4 This is a diagram illustrating louvers 402 of a solar panel constructed according to one or more aspects of the present invention. As shown, louvers 402 are distributed on a top encapsulation layer 308. The size, shape, height, and spacing of the louvers are designed to give the solar panel a desired appearance when viewed from one or more specific lateral angles, and also to maximize the amount of solar energy reaching the photovoltaic cells 306 through the top encapsulation layer 308 (including the louvers).

[0046] Figure 5AThis diagram illustrates the solar irradiation path via a louver layer 502 to a solar panel 500, according to one or more aspects of the invention disclosed herein. As shown, the louver 504 is preferably designed and constructed to maximize the transfer of solar energy to the photovoltaic cells 506 and to give the solar panel a desired appearance when viewed from the side. The design of the louver 504 maximizes performance while satisfying aesthetic requirements. Simulations may include simple ray tracing and take into account the refractive index of the cell surface, the effects of multiple reflections, and the exact position of the sun. Similar factors in the design may include unpolarized light, full absorption of the photovoltaic cells within the louver, simulating a sunny day, and the transparency of the layer. Figure 5A The louvers 504 can be tilted to help collect solar energy internally, thereby increasing the efficiency of the solar panel 500. The louver layer 502 can be a film containing the louvers 504.

[0047] Figure 5B This is a diagram illustrating a solar panel 510 including tilted louvers 512 constructed according to one or more aspects of the invention disclosed herein. The tilted louvers 512 are used, for example, in... Figure 5A As shown, sunlight at a low angle relative to the solar panel is absorbed to block the photovoltaic cell from being viewed from the observer's perspective, and sunlight received at a high incident angle is reflected (in some embodiments, reflected into the interior) onto the photovoltaic cell 514 by the louvers 512.

[0048] Figure 6A This is a graph showing the street visibility index relative to the roof angle of solar panels constructed according to one or more aspects of the present invention. As shown, when the roof angle is close to 90 degrees, more photovoltaic panels are visible (less obstruction from the louvers). Furthermore, at low roof angles, the photovoltaic panels are not visible when viewed from a zero-degree side, but are less obstructed when viewed from a 45-degree side. The parameters used to model these simulation results include the shape and orientation of the louvers (e.g., orthogonal louvers with 100-micrometer spacing), the roof orientation (e.g., south-facing), the roof's geographical location (e.g., Palo Alto, California), day, hour, and other parameters, as well as the refractive index of the matrix and the louvers.

[0049] Figure 6B These are graphs showing the percentage of light transmitted through the louvers relative to the solar panel angle of a solar panel constructed according to one or more aspects disclosed in this invention. As shown, these graphs take into account the annual monthly values ​​and annual averages of the percentage of transmitted light transmitted through the top encapsulation layer including the louvers as a function of the solar panel angle for a particular louver design.

[0050] Figure 7A , 7BFigures 7C and 7D are graphs showing the percentage of light transmitted through the louvers relative to the solar panel angle of a solar panel constructed according to one or more aspects disclosed in this invention. As shown, these graphs consider the annual monthly values ​​and annual average of the percentage of transmitted light transmitted through the top encapsulation layer including the louvers as a function of the solar panel angle for a particular louver design.

[0051] Figure 8A and 8B A portion of a prior art solar panel 800 and a solar panel 802 constructed according to one or more aspects disclosed in this invention are shown. Solar panel 802 enables photovoltaic cells to generate light from nearby... Figure 8A Observed from the vertical viewing angle in the middle, and from Figure 8B In contrast, photovoltaic cells are hidden from more lateral angles. In contrast, existing solar panels 800 allow photovoltaic cells to be seen from both viewing angles.

[0052] Figure 9A and 9B A portion of a prior art solar panel 900 and a solar panel 902 constructed according to one or more aspects disclosed in this invention are shown. Solar panel 902 enables photovoltaic cells to generate light from nearby... Figure 9A Observed from the vertical viewing angle in the middle, and from Figure 9B In contrast, photovoltaic cells are hidden from more lateral angles. In contrast, existing solar panels 900 allow photovoltaic cells to be seen from both viewing angles.

[0053] Figure 10A and 10B A roof tile 1000 is shown, in which a solar panel 1002 constructed according to one or more aspects disclosed in the present invention is installed. When viewed from a substantially vertical viewing angle, the photovoltaic cells 1002 of the roof tile 1000 appear... Figure 10A As can be seen from... Figure 10B When viewed from the side angle shown, the photovoltaic cells 1002 of the roof tile 1000 are hidden or obscured.

[0054] Figure 11A and 11BIncludes photographs and graphs illustrating the steps involved in designing solar panels for one or more residences according to one or more aspects of the invention. The first step is to assess the roof on which the solar panels will be installed. In this case, photographs are taken of the residence, and then geotagging is performed. Data such as area and features, roof spacing, geographic data, and street location advantages are generated from the photographs and geotagging. The solar panels are then designed, rendered, and arranged based on the generated data, taking their cost into consideration. The roof color, type of solar panels to be installed, location film, and other considerations are determined during the solar panel design. The roof kit is then generated, tempered, assembled, laminated, inspected, and transported to the site for installation.

[0055] Figure 12 This is an aerial view of a residential area, with residential solar panels designed for the dwellings within that area, according to one or more aspects of the invention. The residential area in which the dwellings are located may have restrictive contracts requiring certain roof appearances. The solar panels can be designed to meet these restrictive contracts and local laws, and further enhance the attractive appearance of the installation.

[0056] Figure 13 It is a photograph showing a view of a house equipped with solar panels designed and constructed according to one or more aspects disclosed in the present invention.

[0057] Figure 14 It is a photograph showing a view of a house equipped with solar panels designed and constructed according to one or more aspects disclosed in the present invention.

[0058] Figure 15A , 15B Figures 15C and 15D illustrate one embodiment of a top layer (e.g., top layer 310). Figures 15A-15D The top layer 1500 shown is made of glass and includes a jagged surface 1502 that covers the photovoltaic cells 1504 when viewed from a low angle. (See reference first.) Figure 15A The top layer 1500 is shown to have a surface 1502, which is formed with a serrated pattern having a vertical toothed surface 1502A and an inclined toothed surface 1502B. The vertical toothed surface 1502A is formed substantially perpendicular (approximately 90 degrees) to the solar panel structure, and the inclined toothed surface 1502B is formed at an angle between perpendicular to and parallel to the solar panel structure. In some embodiments, this angle is selected based on the installation location of the solar panel so that the solar panel can operate effectively while still being able to conceal the photovoltaic panel when viewed from a low-angle side view. Figure 15A The view is a side view, so the top layer 1500 is not essentially transparent based on the black color on the vertical toothed surface 1502.

[0059] Next reference Figure 15B The top layer 1500 is shown as being viewed from a perspective that is roughly perpendicular to the solar panels. Therefore, the top layer 1500 is mostly transparent in this perspective view.

[0060] Next reference Figure 15C The top layer 1500 is shown residing on the photovoltaic cell layer 1504. From... Figure 15B Observe from roughly the same viewing angle. Figure 15C From this viewing angle, the top layer is mostly transparent, allowing the photovoltaic cell 1504 to be observed through the top layer 1500.

[0061] Next reference Figure 15D ,from Figure 15A Viewed from a similar angle, the top layer 1500 appears as residing within the photovoltaic cell layer 1504. Therefore, due to the serrated surface structure of the top layer, the photovoltaic cells are hidden from view.

[0062] 2. Coated backsheet for solar panels

[0063] Now for reference Figure 16-18 It describes a coated backsheet for solar panels that reflects light in the infrared range to keep the solar panels at a low cell temperature, while also providing low reflectivity in the visible range to color match the backsheet to the cells and improve the aesthetics of the solar panels.

[0064] In the construction industry, physical vapor deposition (PVD) coatings made of alternating layers of dielectrics and metals have been successfully used to reduce heat entering buildings. According to one or more embodiments, novel back panels made of coated plastic films that reflect light in the infrared range also provide low reflectivity in the visible range.

[0065] Figure 16 This is a cross-sectional side view illustrating a tandem solar panel 1600 constructed according to one or more embodiments. The tandem solar panel 1600 includes a top panel 1602, solar cell layers 1604, and a back panel 1606. The top panel 1602 is made of glass in the illustrated embodiment, but may be made of different materials in other embodiments. The solar cell layer 1604 is made of EVA in the illustrated embodiment, but may be made of different materials such as polyolefins in other embodiments. The solar cell layer 1604 includes a plurality of solar cells 1605 enclosed within the EVA material. Sunlight 1608 passes substantially through the top panel 1602 and directly onto the solar cells 1605, or passes between the solar cells to the back panel 1606. The back panel 1606 absorbs some of the sunlight 1608 and reflects some of the sunlight.

[0066] Figure 17 This is a cross-sectional side view showing a coated backplate 1606 constructed according to one or more embodiments. According to some embodiments, a PVD process is used to coat... Figure 17 Layers 1704A-1704D, shown in the image, are deposited on top of substrate 1702. The backplane panel 1606 is made of a transparent or opaque substrate 1702, such as glass, EVA, polyethylene terephthalate (PET), or an alloy of polyphenylene ether and styrene (modified PPO). Substrate 1702 may or may not contain an absorbing material that gives it a black (or any other) color. A thin coating is applied to substrate 1702 consisting of n+1 dielectric modules (1704A, 1704B, 1704C, and 1704D, also referred to as dielectric layers) and n metal layers (1706A, 1706B, and 1706C), where n is an integer (e.g., 1, 2, or 3). The coating of 2n+1 layers is applied as follows: dielectric module / metal layer / dielectric module / metal layer… / dielectric module / substrate, with each metal layer located between two dielectric modules, and the substrate in contact with the dielectric modules. In some embodiments, the number of layers differs from that shown in the embodiment.

[0067] In some embodiments, the dielectric module is a transparent material made of one or more nitride or oxide layers of elements Si, Al, Ti, Zn, Sn, Nb, In, Zr, or any combination of these elements. For example, a 3nm Si3N4 material can be used as a dielectric module, as can a 30nm Si3N4 and 10nm zinc-aluminum oxide stack. The thickness of the dielectric module is preferably between 10nm and 100nm.

[0068] In some embodiments, the metal layer comprises one or more layers of Ni, Cr, Fe, Nb, Ti, Cu, Al, Ag, Au, Pt, or any combination of these metals. For example, an Nb layer is a metal layer. An Nb layer having Ni and Cr layers above or below it is also a metal layer. The thickness of the metal layer is preferably 4 nm to 40 nm.

[0069] According to certain embodiments disclosed in this invention, the backsheet has different properties depending on the specific layer utilized for PVD deposition. For example, a Si3N4 deposition layer can provide an effective barrier against alkaline ions such as Na+. Furthermore, depositing a conductive layer as one layer in the backsheet coating can be used to enhance electrostatic performance. In some embodiments, one or more deposition layers constituting the backsheet are conductive and can be used as part of an energy harvesting mechanism. Specific structures or circuits within this layer can be created by utilizing the PVD deposition layer and subsequently laser etching away the conductive material to generate traces (or circuitry). According to some embodiments, the PVD-formed layer causes the backsheet to absorb light in the visible range, which helps the backsheet match the color of the battery 1605. In some embodiments, the deposition layer is selected to provide low overall radiation absorption (high reflectivity) while maintaining low reflectivity in the visible range to achieve the desired battery color matching while maintaining a lower battery temperature (e.g., providing less heat to the battery compared to some conventional backsheets), thereby improving battery efficiency and energy production.

[0070] Figure 18 This is a graph showing the reflectance spectrum of a solar panel constructed according to one or more embodiments. Figure 18 Spectroscopic examples can be constructed as follows:

[0071] <![CDATA[ layer ]]> <![CDATA[ thickness ]]> <![CDATA[Si3N4]]> 66.7nm Nb 25.1nm <![CDATA[Si3N4]]> 14.2nm <![CDATA[SiO2]]> 38nm <![CDATA[TiO2]]> 18nm PET substrate 0.5mm

[0072] exist Figure 18 In the reflectance spectrum, the infrared wavelength has higher reflectance compared to wavelengths in the visible light range, thus providing high performance with low visible reflectance and high energy reflectance. The total solar reflectance (ISO 9050) is 28% (compared to 6% for the black panel). At a 60-degree incident angle, the visible colors for D65 CIE 1934 are L* = 55, a* = 1, b* = -6 (given a purple matching cell). In contrast, the white back panel has L* > 70, making it mismatched with the cell.

[0073] In some embodiments, the coating is obtained by PVD using commercially available equipment, such as a roll-to-roll process. For example, Si3N4 can be obtained by reactive sputtering a Si target in a plasma made of argon and nitrogen; TiO2 can be obtained by sputtering in argon gas. x TiO2 can be obtained by sputtering a Si target in O2 and Ar plasma; SiO2 can be obtained by sputtering a Si target in Ar plasma; and Nb layers can be obtained by sputtering an Nb target in Ar plasma.

[0074] This PVD coating technology is well known for architectural coatings. Optional functions of the backsheet include electrical conduction for energy harvesting. This can be achieved by laser etching of already conductive intrafilm tracks. The Si3N4 layer used in some exemplary coatings is an effective barrier against alkaline ions such as Na+. In some embodiments, the film's electrical conductivity exhibits good electrostatic properties.

[0075] 3. Solar cell camouflage structure

[0076] Now for reference Figure 19-24 It describes a technique for shading solar panels using specialized constructions of patterned camouflage films, textured backsheets, and colored backsheets.

[0077] Figure 19 A cross-sectional side view is shown, which illustrates the solar cell 1900. Figure 19 The solar cell 1900 shown includes a silicon wafer 1906 used as a photovoltaic material. Typically, a polymer front panel 1904 is placed on top of the silicon wafer 1906, and a glass layer 1902 (e.g., a top plate) is placed on top of the polymer front panel 1904. The glass layer 1902 may comprise amorphous silicon dioxide. The glass layer 1902 may also comprise other transparent materials. In some embodiments, the solar cell 1900 is obscured, making it difficult for an observer to see and causing the solar cell 1900 to blend into the background or appear similar to its surroundings. Figure 21B A solar cell 2108 is shown, which is not incorporated into the surrounding roof tiles 2110 (collectively referred to as solar tiles 2106). The solar cell 2108 is visible toward the center of each roof tile 2110. Other photovoltaic materials can be used on the sides of the silicon wafer in the solar cell, and it will still benefit from the shading and camouflage techniques described herein.

[0078] This invention discloses methods for visually masking or camouflaging solar cells by blending them into their surroundings and / or obscuring silicon wafers from observation. According to some embodiments, one system uses a patterned coating to camouflage the solar cell.

[0079] A. Patterned coatings for camouflaging solar cells

[0080] Solar cells can be visually camouflaged by using a camouflage pattern to blend them into the rest of the solar tiles. This camouflage pattern comprises a patterned, thin, transparent coating. The pattern includes blocks of specific shapes (e.g., squares, rectangles, circles, or arbitrary shapes). For example, the camouflage shape may include a square that is lighter than the lightest color observed when viewing the solar cell. This square (or other geometric pattern) pattern may be randomly distributed around the solar cell area. In some embodiments, the coating allows transmission of more than 50% of the solar spectrum but slight reflection (reflecting 1 to 20% of the solar spectrum). That is, the coating reflects a portion of the solar spectrum that the photovoltaic material can absorb.

[0081] Random patterns of shapes (squares or other shapes) can be generated using the Ising model employing the Metropolis algorithm. Specifically, the Metropolis dynamics algorithm can be applied near the critical temperature to generate images with good scale invariance suitable for shading and camouflaging solar cells. However, other methods such as random spatial processes, Gaussian random domains (e.g., domains generated using Hurst's spectral distribution law), or natural patterns such as images of stones can be used to obtain both small-scale and large-scale features, enabling the shading of solar cells. Figure 20A The output obtained using the Ising model with the Metropolis algorithm is shown. Figure 20B This illustrates one embodiment of the Gaussian domain. These random patterns have the advantage of appearing natural and non-repeating. Optionally, the colors of the tiles and patterns can vary depending on the tiles to provide a more natural look.

[0082] This random pattern can be used to generate coatings with similar patterns. Different patterns can be obtained depending on specific parameters, such as the size and shape of the object.

[0083] The coating itself comprises one or more material layers applied to a transparent substrate, such as glass or a polymer sheet, like PET, in areas preferably covering 10%-90% of the total area of ​​the solar cell. The material layers can be deposited onto the transparent substrate using PVD or other techniques known to those skilled in the art. PVD or other techniques must be able to form the desired coating thickness and be compatible with the materials in the coating. For example, Ti, Zn, Si, Al, Sn, In, Cu, Zr, Nb, or Sb oxides or nitrides can be used as one or more layers formed on the substrate. Other layers may consist solely of metals such as Nb, Ag, Cu, Fe, Cr, Ni, Al, or Ti, or combinations thereof. An exemplary coating comprises 50 nm Si3N4 applied to glass or PET by reactive sputtering of a Si target in a plasma containing Ar and N2, as is widely used in PVD. Preferred deposition can be achieved using a mask (or other techniques known to those skilled in the art). For example, the mask may be a mask containing a specific pattern to be deposited. Plate. Other techniques that can be used to generate deposited patterns include photolithography or printing techniques. For example, an organic material (e.g., an organic polymer) with a negative pattern can be printed on a glass surface. The polymer can be used as a mask for a layer coated using PVD (or other techniques). The organic material can then be removed, for example, by burning off the material in an oven. In some embodiments, the coating is achieved by sublimation printing or other ink printing techniques.

[0084] The coating can be applied to Figure 19 Glass layer 1902 (front or back) or Figure 19 The coating is in the form of a front panel layer 1904 (front or back). The coating can also be printed directly onto the glass or the front panel. Alternatively, the coating can be contained within... Figure 19 The independent layer above the silicon wafer shown.

[0085] Figure 21A This illustration shows an example of a coating with a camouflage pattern applied to a solar cell 2102 according to an embodiment of the present invention. The camouflage pattern obscures the solar cell 2102 to separate it from the surrounding material and makes the solar tile 2100 appear more uniform (e.g., making it difficult to see where the conventional roofing material 2104 ends and where the solar cell 2102 begins). Figure 21B The solar cell 2108 without the camouflage film is shown. The solar cell 2108 is visible (facing the center of each solar tile 2106).

[0086] In some embodiments, a textured substrate may be used to further enhance the masking effect of the patterned film. Figures 22A-22DExemplary camouflage coatings formed on a textured substrate according to certain embodiments of the present disclosure are shown. The texture may include raised or recessed lines along a certain direction, raised or recessed square patterns, pebble textures, or other textures.

[0087] B. Backplate with battery color matching

[0088] According to certain embodiments disclosed in this invention, another way to shield the solar cells within the solar tile is to match the backsheet color to the silicon wafer of the photovoltaic cell and / or to create a textured backsheet.

[0089] In some embodiments, the silicon wafer surface includes a pyramidal morphology. Figure 23 The microstructure of the silicon surface is shown in a series of electron micrographs. When the silicon (e.g., Si(111)) surface is exposed, a pyramidal morphology is obtained. If different silicon surfaces, such as Si(110) or Si(100) surfaces, are exposed, the morphology of the silicon surface may be different. Similarly, if the photovoltaic cell includes another semiconductor, such as gallium nitride, gallium arsenide, gallium phosphide, or another semiconductor, the morphology may be different.

[0090] According to some embodiments disclosed in this invention, the backsheet includes a textured polymer layer, such as PET, polycarbonate, or other suitable polymers. The textured polymer layer may have a pyramidal morphology, which, together with... Figure 23 The structure exhibited in the Si(111) surface shown is similar. A coating can then be applied on top of a textured polymer layer. In some embodiments, the coating has a similar color (or color array) to the cell (or specifically, the silicon wafer or photovoltaic cell). The result of the coating / film on top of the polymer backsheet is a film that matches the very complex color behavior observed when viewing conventional cells and silicon wafers. If the silicon morphology is different, for example, it contains three-dimensional features, the backsheet can include similar features (instead of pyramidal features). In some embodiments, the backsheet can include glass or other transparent materials that do not need to be polymer materials.

[0091] Textured polymer (e.g., PET) backsheets can be synthesized using various techniques. For example, a polymer injection molding process can be used to synthesize a textured backsheet by first generating a master mold. This method generates a master mold. This master mold can be a metal master mold formed by preparing a metal preform and subsequently laser-cutting (or other forming methods, such as etching) to insert the desired features into the metal preform. For example, a pyramidal feature can be laser-cut or otherwise formed into the metal preform. Alternatively, the master mold can be a glass master mold formed by laser cutting or using other deposition or etching techniques such as electroforming. Other techniques known to those skilled in the art can also be used to form the master mold. The resulting master mold will contain negative indentations of features; for example, a pyramidal feature in the resulting film will appear as a pyramidal recess in the master mold.

[0092] According to some embodiments, a mold "matrix" can be generated using both positive and negative indentations to enable the further generation of additional molds for producing a textured polymer backsheet. That is, a "matrix" mold containing characteristic negative indentations can be used to generate one or more "other matrices" with characteristic positive indentations to be formed in the textured polymer backsheet. One or more "other matrices" with positive indentations can be used to generate one or more negative molds subsequently used to form the textured polymer backsheet. In some cases, it is desirable to generate both a "matrix" and "other matrices" because this enables the generation of additional molds for forming the textured polymer backsheet, which may be necessary in cases of mold loss or feature degradation due to use. Additional molds must also be generated when increasing production volume.

[0093] After the master mold has been produced, it can be used to form a textured polymer backing. For example, the master mold can be used as part of a polymer injection molding process to form a textured backing. The master mold can be inserted into a housing (e.g., a mold), and molten polymer (or other material) can be poured into the mold and allowed to dry. The textured backing will have positive features such as pyramidal features, and... Figure 23 The silicon shown is similar. Quality standard testing can be performed on the textured polymer backplane.

[0094] In some embodiments, polydimethylsiloxane (PDMS) soft lithography can be used to produce the master mold and textured polymer backsheet. Other manufacturing techniques can be used to produce the master mold and textured polymer backsheet. In some embodiments, the resulting textured polymer backsheet includes desired surface features (e.g., surface features that match the surface topography of a glass surface). In some embodiments, glass (silica or another transparent material) is used instead of a polymer (e.g., PET) backsheet as the backsheet substrate.

[0095] One or more layers can be coated onto a backplane substrate (textured or other substrates) to produce a specific color configuration that helps to visually conceal the cell (specifically, the silicon wafer of a photovoltaic cell (or a wafer formed from other semiconductor materials)). The coating on the top or bottom of the backplane substrate can consist of one or more layers. It is not necessary to coat the entire surface of the backplane substrate. Optionally, 10%–90% of the entire surface area of ​​the backplane substrate is coated. The coating can be formed using PVD or another technique known to those skilled in the art. PVD or other techniques form the desired coating thickness and are compatible with the materials in the coating. For example, oxides or nitrides of Ti, Zn, Si, Al, Sn, In, Cu, Zr, Nb, Sb can be used as one or more layers formed on the backplane substrate. Other layers can individually contain metals such as Nb, Ag, Cu, Fe, Cr, Ni, Al, Ti, or combinations thereof. Figure 24 Coatings 2400 (TiO2), 2402 (Al), and 2404 (TiO2) according to certain embodiments are shown. TiO2 / Al / TiO2 layers (thickness in...) Figure 24 The image shows a purple-like color at 100nm / 4nm / 5nm. In some embodiments, the coating includes a Si layer on the substrate and an indium tin oxide (ITO) layer on the Si layer (e.g., substrate / Si / ITO) or a Si3N4 layer on the Si layer (e.g., substrate / Si / Si3N4). Optionally, the entire backplane is textured. In some embodiments, a textured backplane is used to simulate an actual wafer (e.g., to serve as a replica wafer with the same color as the actual wafer). The coating may comprise a silicone-based coating or a solvent-based ink system.

[0096] Patterned coatings, patterned coatings on textured substrates, textured backsheets, or coated backsheets can all be used together to help visually shield solar cells and blend them into their environment (such as the rest of a solar tile), thereby concealing or disguising solar cells.

[0097] The foregoing disclosure is not intended to limit the invention to the exact form or specific field of the disclosed uses. Therefore, it is contemplated that various alternative embodiments and / or modifications (whether specifically described or implied herein) of the invention are possible with reference to this invention. Those skilled in the art will recognize, using the embodiments of the invention thus described, that variations in form and detail may be made without departing from the scope of the invention. Therefore, the invention is limited only by the claims.

[0098] In the foregoing description, the invention has been described with reference to specific embodiments. However, as those skilled in the art will understand, the embodiments disclosed herein can be modified or implemented in various other ways without departing from the spirit and scope of the invention disclosure. Accordingly, this specification should be regarded as illustrative and intended to teach those skilled in the art various ways of making and using the disclosed systems, methods, and computer program products. It should be understood that the forms of disclosure shown and described herein should be considered as representative embodiments. Equivalent elements, materials, processes, or steps may be used instead of those representatively shown and described herein. Moreover, as will fully appreciate by those skilled in the art after benefiting from this disclosure, certain features of the invention can be used independently of other features employed.

[0099] As used herein, the terms “comprising,” “including,” “containing,” “having,” or any contextual variations thereof are intended to cover non-exclusive inclusion. For example, a process, product, article of manufacture, or apparatus that includes a list of elements is not necessarily limited to those elements, but may include other elements not expressly listed or inherent to those processes, products, articles of manufacture, or apparatus. Furthermore, unless expressly stated otherwise to the contrary, “or” means inclusive “or,” not exclusive “or.” For example, the condition “A or B” satisfies any of the following conditions: A is real (or exists) and B is fictitious (or does not exist); A is fictitious (or does not exist) and B is real (or exists); and both A and B are real (or exist).

[0100] Although steps, operations, or calculations may be listed in a specific order, this order can vary in different embodiments. In some embodiments, with respect to the multiple steps shown sequentially in this specification, some combinations of these steps in alternative embodiments may be performed simultaneously. The sequence of operations described herein may be interrupted, paused, reversed, or controlled by another process.

[0101] It should also be understood that one or more elements described in the figures / figures may be implemented in a more separate or integrated manner, or even removed or rendered inoperable in certain circumstances, such as for use in a particular application. Furthermore, any directional arrows in the figures / figures should be considered illustrative only and not restrictive, unless otherwise specifically stated.

Claims

1. A solar panel, characterized in that, include: roof; Polymer front panel; A photovoltaic cell layer adjacent to the polymer front panel, the photovoltaic cell layer comprising a plurality of photovoltaic cells having a first morphology encapsulated in a photovoltaic cell layer material; A textured backplate having a second morphology similar to the first morphology; and A silicon layer is coated on the surface of the textured backsheet facing the photovoltaic cell layer, wherein the color of the textured backsheet coated with the silicon layer matches the color of the plurality of photovoltaic cells.

2. The solar panel according to claim 1, wherein the textured backsheet comprises polyethylene terephthalate.

3. The solar panel of claim 1, wherein the textured backsheet comprises glass.

4. The solar panel according to claim 1, wherein the textured backsheet further comprises a first titanium dioxide layer, an aluminum oxide layer, and a second titanium dioxide layer.

5. The solar panel of claim 4, wherein at least some of the first titanium dioxide layers have a thickness of 90 nm to 110 nm.

6. The solar panel of claim 1, wherein the photovoltaic cell layer comprises silicon having a morphology having a first shape feature; and the textured backsheet comprises a polymer having a morphology having the first shape feature.

7. The solar panel according to any one of claims 1-6, wherein the photovoltaic cell layer comprises silicon having a pyramidal morphology; and the textured backsheet comprises a polymer having a pyramidal morphology.

8. The solar panel of claim 1, wherein the textured backsheet comprises a metal layer and etched traces forming circuitry.

9. A solar panel, characterized in that, include: The invention includes multiple photovoltaic cells encapsulated in a photovoltaic layer material, wherein the multiple photovoltaic cells include a surface having a first morphology; The top plate adjacent to the first surface of the photovoltaic layer material; as well as A textured backsheet layer has a second morphology similar to a first morphology of the plurality of photovoltaic cells, wherein the textured backsheet layer includes a thin coating that reflects light matching the color of the plurality of photovoltaic cells, thereby producing a specific color configuration that helps to visually obscure or camouflage the plurality of photovoltaic cells, wherein: The thin coating has a higher reflectivity for infrared wavelengths than for visible wavelengths, and includes: n+1 dielectric layers; and There are n metal layers, each of which is sandwiched between two of the n+1 dielectric layers, where n is a positive integer. The textured backsheet layer is adjacent to the second side of the photovoltaic layer material, which is opposite to the first side.

10. The solar panel of claim 9, wherein the top plate is a layer of glass.

11. The solar panel of claim 9, wherein the textured backsheet layer comprises a polymer.

12. The solar panel of claim 9, wherein the second morphology includes a pyramidal feature.

13. The solar panel of claim 9, wherein the textured backsheet layer comprises one or more color coatings.

14. The solar panel of claim 9, wherein a silicon layer is coated on the textured backsheet layer.

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