Structural composite panel

Abstract

A structural composite panel is provided. The structural composite panel comprises a first layer, at least one photovoltaic cell arranged on the first layer, a resin layer containing the resin, and a protective layer arranged on the resin layer. The first layer comprises a resin and a structural reinforcement. Part of the first layer includes the structural reinforcement encapsulated in the resin, and part of the first layer does not include a structural reinforcement. The resin layer is arranged on the at least one photovoltaic cell.

Description

[0001] The present description refers to a fiber-reinforced composite panel and, in particular, to a fiber-reinforced composite panel with energy storage.

[0002] Photovoltaic cells, commonly known as photovoltaic cells, are frequently used to convert sunlight into electrical energy. Traditionally, these cells are installed on roofs, in solar parks, and in stationary installations. However, there is growing interest in integrating photovoltaic cells into mobile platforms, such as vehicles, to harness solar energy while on the go.

[0003] Existing approaches to integrating photovoltaic cells into vehicles have their limitations. Photovoltaic cells on vehicle roofs are often bulky, heavy, and disrupt the vehicle's aerodynamics. Furthermore, visible photovoltaic cells can detract from the vehicle's aesthetics. Additionally, the lifespan of photovoltaic cells is affected by harsh environmental conditions such as temperature fluctuations, mechanical stress, and UV radiation.

[0004] US 2012 / 0312358A1 describes a high-reliability solar cell module and a method for its fabrication. The solar cell module comprises first and second solar cell elements, each having a semiconductor substrate and an output pickup electrode; a circuit film that electrically connects the first and second solar cell elements; and a sealing material positioned between the circuit film and the second surface of the first and second solar cell elements. The sealing material has a through-hole, and the circuit film has: a base film with a protruding section that extends toward the second surface of the solar cell element; and a wiring conductor that electrically connects the output pickup electrode of the first solar cell element and the output pickup electrode of the second solar cell element.

[0005] While prior art methods and systems attempt to create lightweight structures while simultaneously incorporating photovoltaic cells and can achieve their specific purpose, the object of the invention is to provide a new and improved solution for integrating photovoltaic cells into mobile platforms.

[0006] The object of the invention is achieved by means of a structural composite panel. The structural composite panel comprises a first layer, at least one photovoltaic cell arranged on the first layer, a resin layer containing the resin, and a protective layer arranged on the resin layer. The first layer comprises a resin and a structural reinforcement. Part of the first layer includes the structural reinforcement encapsulated in the resin, and part of the first layer does not include a structural reinforcement. The resin layer is arranged on the at least one photovoltaic cell. The structural reinforcement is a fiber comprising at least one of the following elements: glass, basalt, flax, hemp, pineapple, or cellulose.

[0007] According to another embodiment, the structural reinforcement comprises a reinforcing carbon fiber that conducts electrical current to the at least one photovoltaic cell.

[0008] According to another embodiment, the structural reinforcement is a structural fiber mixed with a non-structural 3D seam comprising at least one of the following elements: polycarbonate, nylon, polyethylene or polypropylene, to solidify the fiber and a preform.

[0009] According to a further embodiment, the at least one photovoltaic cell comprises at least one of the following elements: monocrystalline silicon, polycrystalline silicon, a thin film or indium tin oxide.

[0010] According to another embodiment, the at least one photovoltaic cell is arranged on a part of the first layer that does not have any structural reinforcement.

[0011] According to another embodiment, the at least one photovoltaic cell is arranged on a part of the first layer that has both structural reinforcement and no structural reinforcement.

[0012] According to another embodiment, the resin comprises at least one of the following elements: polycarbonate or acrylic.

[0013] According to another embodiment, the protective layer is a hard layer.

[0014] According to another embodiment, the protective layer is a reinforced glass layer.

[0015] According to another embodiment, the structural composite panel is a vehicle roof panel.

[0016] According to a further embodiment, the structural reinforcement comprises a structural fiber reinforcement arranged around a circumference of the outer vehicle body panel and a glass fiber structural reinforcement arranged in a region outside the circumference. The structural fiber reinforcement is arranged in a region that connects a first region of the periphery with a second region of the periphery in a cross-car configuration.

[0017] According to another embodiment, the structural fiber reinforcement is arranged in an area outside the arrangement of a photovoltaic cell.

[0018] According to another embodiment, the at least one photovoltaic cell is encapsulated with a second resin.

[0019] According to another embodiment, the resin is a transparent resin.

[0020] According to another embodiment, the resin is at least one of the group of thermosetting or thermoplastic plastics.

[0021] To understand the structural composite panel, a method is described which includes process steps that describe the formation of the features of the structural composite panel according to the invention and the embodiments. The method comprises the local application of a structural reinforcement to a first layer comprising a resin. A portion of the first layer comprises the structural reinforcement encapsulated in the resin, and a portion of the first layer does not include any structural reinforcement. The method also includes the application of at least one photovoltaic cell to the first layer. The at least one photovoltaic cell is arranged on a portion of the first layer that does not have structural reinforcement. The method further includes encapsulating the photovoltaic cell and the structural reinforcement by means of resin infusion and applying a protective layer to the encapsulated photovoltaic cell and the resin infusion.

[0022] The above features and advantages, as well as other features and advantages of the system and method described here, are readily apparent from the detailed description, including the claims and examples, when considered in conjunction with the accompanying drawings.

[0023] The present description will be better understood with the help of the detailed description and the attached drawings, whereby: Fig. 1 is a perspective view showing an example of a vehicle with a structural composite panel containing at least one photovoltaic cell. Fig. 2 a side cross-sectional view, which shows the Fig. Figure 1 illustrates a structural composite panel, wherein the structural composite panel comprises a first layer, a photovoltaic cell, a resin layer and a protective layer. Fig. 3 is a top view, which shows the in Fig. Figure 2 shows the first layer, which comprises a resin and a structural reinforcement. Fig. 4 is a side cross-sectional view, which shows the in Fig. Figure 1 illustrates a structural composite panel, wherein the structural composite panel comprises a first layer, a photovoltaic cell, an optical interconnect layer and a reinforcing glass layer. Fig. 5 is a flowchart that shows a process for producing the in Fig. 2 and Fig. 4 structural composite panels are illustrated.

[0024] Several examples of the description, illustrated in the accompanying drawings, are now referred to in detail. Wherever possible, the same or similar reference numbers are used in the drawings and the description to indicate identical or similar parts or steps. The following description is merely exemplary and is not intended to limit the present description, application, or use.

[0025] Photovoltaic cells are exposed to various environmental factors, including temperature fluctuations, mechanical stress, and UV radiation, especially when used in vehicles. Conventional rooftop installations subject the cells to harsh conditions, which reduces their lifespan. By embedding the photovoltaic cells in the vehicle body panels, they are protected from external influences, extending their lifespan and ensuring consistent energy production throughout the vehicle's lifetime. The composite structural panels presented here enable lightweight, aesthetically pleasing, and durable photovoltaic solutions for vehicles. Embedding photovoltaic cells directly into the vehicle body panels, including the roof, results in a lighter structure, increased customer satisfaction, and improved overall performance and sustainability of solar-powered vehicles.

[0026] In Fig. Figure 1 shows a perspective view of a vehicle 10 with a structural composite panel 12 as described herein. The structural composite panel 12 is shown with an exemplary vehicle 10 and is depicted as a roof panel. Although the vehicle 10 is shown as a passenger car and as a roof panel, the structural composite panel 12 can also be used in various other vehicle types and in other locations on the vehicle. For example, the structural composite panel 12 can be used in watercraft such as boats or in aircraft such as drones or passenger planes. Furthermore, the structural composite panel 12 can be used in a door panel, a side panel, at least part of the hood and / or the trunk, and so on.

[0027] In Fig. Figure 2 shows a side cross-sectional view of the structural composite panel 12 as described herein. The structural composite panel 12 comprises a first layer 14, at least one photovoltaic cell 16, a resin layer 18, and a protective layer 20. As shown in Fig. As shown in Figure 2, the first layer 14 comprises a resin 22, which may, for example, contain a polymer. The polymer may be a thermosetting polymer or a thermoplastic polymer that is essentially transparent when free of other materials (e.g., fibers). In one example, the polymer may be a thermosetting polymer comprising at least a benzoxazine, a bis-maleimide (BMI), a cyanate ester, an epoxy, a phenol (PF), a polyacrylate (acrylic), a polyimide (PI), an unsaturated polyester, a polyurethane (PUR), a vinyl ester, a siloxane, copolymers thereof, and combinations thereof.In another example, the polymer can be a thermoplastic polymer, including polyethyleneimine (PEI), polyamide-imide (PAI), polyamide (PA) (for example, Nylon 6, Nylon 66, Nylon 12), polyetheretherketone (PEEK), polyetherketone (PEK), a polyphenylene sulfide (PPS), a thermoplastic polyurethane (TPU), polypropylene (PP), polycarbonate / acrylonitrile butadiene styrene (PC / ABS), high-density polyethylene (HDPE), polyethylene terephthalate (PET), polymethyl methacrylate (PMMA), polycarbonate (PC), polyaryletherketone (PAEK), polyetherketoneketone (PEKK), copolymers thereof, and combinations thereof. In some examples, resin 22 can contain several polymers and, in addition, an opaque polymer, for example, in areas of low or no transparency.

[0028] Fig. Figure 3 is a top view showing the first layer 14 with a structural reinforcement 24 arranged in a portion of the first layer 14. The structural reinforcement 24 can be arranged in all or only parts of the first layer 14 and serves to reinforce the structural composite panel 12. It is evident that the configuration of the structural reinforcement 24 differs from that shown in Figure 3. Fig. The 3 shown may differ, and the structural reinforcement 24 may be located in places other than shown. Fig. The structural reinforcement 24 can be arranged as shown in Figure 3. It can have different lengths and / or orientations to achieve a desired strength for the structural composite panel 12.

[0029] In one example, the structural reinforcement can contain 24 fibers. Some examples of suitable fiber materials are carbon fibers (for example, carbon black, carbon nanotubes, talc, polyacrylonitrile fibers, pitch precursors, and the like), glass fibers (for example, glass fiber, quartz), basalt fibers, aramid fibers (for example, KEVLAR®, polyphenylenebenzobisoxazole (PBO)), polyethylene fibers (for example, ultra-high molecular weight polyethylene (UHMW)), polypropylene fibers (for example, high-strength polypropylene), natural fibers (for example, cotton, flax, hemp, cellulose, spider silk, pineapple), and combinations thereof. In one example, the structural reinforcement can contain 24 reinforcing carbon fibers that conduct electricity. For example, carbon fiber is an electrical conductor and can itself conduct electricity.In another non-restrictive example, the structural reinforcement encompassing the fibers may include an electrical wire (for example, a copper wire) and / or tapes (for example, copper) embedded in the fiber, the electrical wire and / or tapes being configured to conduct the electrical current.

[0030] Furthermore, the structural reinforcement 24 can be a single fiber (in the dry state) or a mixed fiber (in the dry state) blended with a non-structural 3D seam (for example, polycarbonate, nylon, polyethylene, polypropylene, and the like). The mixed fiber can, for example, contain carbon and polycarbonate (PC), carbon and polyamide 6 (PA6), carbon and polyamide 12 (PA12), glass and polycarbonate (PC), glass and polyamide 6 (PA6), and the like. The single fiber and / or the mixed fiber can be stitched, laid, or otherwise placed onto the resin 22, and in some cases, it can be bonded to the resin 22 by force and / or heat (for example, by overmolding the single fiber and / or mixed fiber with the resin 22).If an overmold layer is used, it can be made of the same or a similar material as resin 22 to avoid problems with refractive index mismatch and image distortion. Dissimilar resins can also lead to adhesion problems at the interface between the overmold layer and resin 22.

[0031] The structural reinforcement 24 can contain a combination of materials within the first layer 14. For example, the structural reinforcement 24 can contain carbon fibers located around a perimeter 26 of the first layer 14, and it can contain glass fibers used in an area outside the perimeter 28. The periphery 26 can comprise an outer edge of the first layer 14. For example, the perimeter 26 can comprise approximately 10% of the width W of the first layer 14. In this context, the term "approximately" is familiar to those skilled in the art. Alternatively, the term "approximately" can also be understood to mean plus or minus 1%. It is self-evident that the perimeter 26 can also comprise other lengths or percentages of the width (for example, 5%, 15%, 20%, and so on).If a structural reinforcement 24 (for example, glass fiber) is arranged in the non-peripheral region 28, the structural reinforcement 24 in the non-peripheral region 28 can extend in a crosswise configuration or transversely across the first layer 14 from a first section of the structural reinforcement 24 in the peripheral region 26 to a second section (or opposite region) of the structural reinforcement 24 in the peripheral region 26. Furthermore, the structural reinforcement 24 in the non-peripheral region 28, extending in the crosswise configuration or transversely across the first layer 14 from a first section of the structural reinforcement 24 in the peripheral region 26 to a second section, can be arranged outside the location of the photovoltaic cell 16.

[0032] As in Fig. As shown in Figure 2, at least one photovoltaic cell 16 is arranged on the first layer 14. The photovoltaic cell 16 comprises an electronic device that converts light energy into electricity through a photovoltaic effect. The at least one photovoltaic cell 16 can be made of, for example, monocrystalline silicon, polycrystalline silicon, cadmium telluride, a thin film, indium tin oxide, or the like. In some cases, the photovoltaic cells 16 can be opaque or essentially opaque, which allows for optimal energy storage. In other cases, the photovoltaic cells 16 can be transparent or essentially transparent, which offers optimal visibility. In one example, if each photovoltaic cell 16 is partially transparent, it can have a degree of transparency between approximately 30% and 50%. In this context, the term "approximately" is familiar to those skilled in the art.Alternatively, the term "approximately" can also be understood to mean plus or minus 1%.

[0033] In some cases, the photovoltaic cell 16 is generally arranged on a portion of the first layer 14 that does not have a structural reinforcement 24. However, it is understood that the photovoltaic cell 16 can also be arranged on a portion of the first layer 14 with a structural reinforcement 24. In one example, the structural composite panel 12 can contain both transparent or substantially transparent photovoltaic cells 16 and opaque photovoltaic cells 16. In this example, the photovoltaic cells 16 that are transparent or substantially transparent can be arranged at a periphery 26 where the structural reinforcement 24, the resin layer 18, and the protective layer 20 are also transparent or substantially transparent. Furthermore, in this example, the photovoltaic cells 16 that are opaque can be arranged in a non-peripheral region 28 where the structural reinforcement 24 is located.

[0034] As in Fig. As shown in Figure 2, the resin layer 18 is arranged on and encapsulates the at least one photovoltaic cell 16. The resin layer 18 can also be arranged on the first layer 14 at locations where there is no photovoltaic cell 16 on the first layer 14. The resin layer 18 can consist of the same or a similar material as the resin 22 in the first layer 14. For example, the resin layer 18 can consist of polycarbonate or acrylic. The resin layer 18 can be transparent or at least partially transparent (for example, translucent) and thermoset or thermoplastic.

[0035] As in Fig. As shown in Figure 2, the protective layer 20 is arranged on the resin layer 18. The protective layer 20 provides UV and / or scratch protection for the structural composite panel 12. The protective layer 20 can consist wholly or partially of a rigid but transparent material. This rigid and transparent material can have a wear-resistant and scratch-resistant hard layer with a thickness of a few micrometers up to about 0.1 millimeters (mm) or more. In this context, the term "about" is familiar to those skilled in the art. Alternatively, the term "about" can also be understood to mean plus or minus 0.01 mm. In some cases, the protective layer 20 can comprise several material layers. For example, the protective layer 20 can be a silicone hard coating with a film sandwiched between a poly(methyl methacrylate) sheet (PMMA) and a transparent polycarbonate sheet (PC).In another example, the protective layer can contain a clear coat film that provides an optically transparent, scratch-resistant "Class A" surface. It goes without saying that the protective layer 20 can also consist of other similar materials than those mentioned.

[0036] Fig. Figure 4 shows a structural composite panel 12 with a first layer 14, at least one photovoltaic cell 16 arranged on the first layer 14, an optical bonding layer 30 arranged on the at least one photovoltaic cell 16 and / or the first layer 14, and a reinforced glass layer 32 arranged on the optical bonding layer 30. The first layer 14 and / or the at least one photovoltaic cell 16 correspond to the layers described above.

[0037] The optical bonding layer 30 is designed to bond the at least one photovoltaic cell 16 and / or the first layer to the subsequent layers (for example, the reinforced glass layer 32) without impairing the optical properties of the structural composite panel 12. The optical bonding layer 30 is formed from a transparent adhesive material that has, for example, a transparency of approximately 75–90%. In this context, the term "approximately" is familiar to those skilled in the art. Alternatively, the term "approximately" can also be understood to mean plus or minus 1% transparency. The transparent adhesive material can be a thermosetting optical binder made of ethylene-vinyl acetate (EVA) or a thermoplastic optical binder made of polyvinyl butyral (PVB). The optical bonding layer 30 can be between approximately 0.01 millimeters (mm) and approximately 1 mm in size. In this context, the term "approximately" is familiar to those skilled in the art.Alternatively, the term "approximately" can also be understood to mean plus or minus 0.1 mm.

[0038] As in Fig. As shown in Figure 4, the reinforced glass layer 32 is arranged on and bonded to the optical bonding layer 30. The reinforced glass layer 32 provides scratch resistance and damage resistance to the structural composite panel 12. The reinforced glass layer 32 can, for example, consist of heat-tempered glass, which is heated to a temperature below its melting point and then cooled. Furthermore, the reinforced glass layer 32 can be formed, for example, from chemically tempered glass, prestressed glass, soda-lime glass, alkali aluminosilicate flat glass, a ceramic material, or a glass-ceramic, and so on, with an individual thickness of approximately 0.3 mm to approximately 3.0 mm. In this context, the term "approximately" is familiar to those skilled in the art. Alternatively, the term "approximately" can also be understood to mean plus or minus 0.1 mm.

[0039] With reference to Fig. Section 5 presents a method 100 for producing the structural composite panel 12 in accordance with the present description. The method begins in block 102.

[0040] Block 102 shows the local application of the structural reinforcement 24 to the first layer 14. The application of the structural reinforcement 24 can involve sewing the structural reinforcement 24 (for example, a fiber) locally onto or into the resin 22 of the first layer 14. In a specific example, a needle and a roving spool can sew the structural reinforcement 24, including a fiber, into the resin 22, as shown in Fig. Figure 3 illustrates this. It goes without saying that applying the structural reinforcement 24 may also involve other techniques. Procedure 100 then proceeds to block 104.

[0041] Block 104 shows the placement of at least one photovoltaic cell 16 on the first layer 14. The placement of the at least one photovoltaic cell 16 may, for example, involve using a robot to place each photovoltaic cell 16 on a portion of the first layer 14 that does not include the structural reinforcement 24. In some cases, placing a photovoltaic cell 16 may involve arranging the photovoltaic cell 16 over a portion of the first layer 14 containing the structural reinforcement 24. Each photovoltaic cell 16 may be incorporated into the first layer 14 prior to step 106. In some cases, the incorporation of each photovoltaic cell 16 may involve the use of a consumable, "tearable" protective layer, for example, e-paper, to protect the photovoltaic cells 16 during the manufacturing steps. Process 100 then proceeds to Block 106.

[0042] Block 106 shows the encapsulation of the at least one photovoltaic cell 16 and the structural reinforcement 24 of the first layer 14, for example by resin infusion. The resin infusion can involve placing the first layer 14 and the photovoltaic cell(s) 16 located on it into a mold in a dry state. A flexible membrane, for example a vacuum bag, is then sealed against the edges of the mold with adhesive tape (for example, sealing tape). The first layer 14 and the photovoltaic cell(s) 16 are then placed under vacuum in the mold. Due to atmospheric pressure, liquid resin is forced through the dry structural reinforcement 24 of the first layer 14 and wets the structural reinforcement 24 and the photovoltaic cell(s) 16. The liquid resin penetrates the structural reinforcement 24 of the first layer 14 and the photovoltaic cell(s) to form the resin layer 18.In some cases, when the optical bonding layer 30 is used, block 106 comprises encapsulating the at least one photovoltaic cell 16 with the optical bonding layer 30. The process 100 then proceeds to block 108.

[0043] Block 108 shows how the protective layer 20 is applied to the resin layer 18. If an optical bonding layer 30 and a reinforced glass layer 32 are used, Block 108 shows the application of the reinforced glass layer 32 to the optical bonding layer 30. The protective layer 20 and / or the reinforced glass layer 32 can be applied to the resin layer 18 or the optical bonding layer 30, for example, using a robot.

[0044] The structural composite panel 12 described herein offers advantages and benefits compared to the prior art. Photovoltaic cells are exposed to various environmental factors, including temperature fluctuations, mechanical stress, and UV radiation. Furthermore, in conventional rooftop installations, the cells are subjected to harsh conditions, which impairs their lifespan. By embedding the photovoltaic cells in the vehicle body panels, they are protected from external influences, extending their service life and ensuring consistent energy generation throughout the vehicle's lifetime. Embedding photovoltaic cells directly into the vehicle body panels, including the roof panels, results in lightweight construction, increased customer satisfaction and aesthetics, as well as improved overall performance and sustainability of solar-powered vehicles.

Claims

[1] Structural composite panel (12), comprising: a first layer (14), comprising a resin (22); and a structural reinforcement (24), wherein part of the first layer (14) comprises the structural reinforcement (24) encapsulated in the resin (22) and part of the first layer (14) does not comprise a structural reinforcement (24); at least one photovoltaic cell (16) arranged on the first layer (14); a resin layer (18) comprising the resin (22), wherein the resin layer (18) is arranged on the at least one photovoltaic cell (16); and a protective layer (20) arranged on the resin layer (18); and wherein the structural reinforcement (24) is a fiber comprising at least one of the following elements: glass, basalt, flax, hemp, pineapple or cellulose. [2] Structural composite panel (12) according to claim 1, wherein the structural reinforcement (24) comprises a reinforcing carbon fiber which conducts electric current to the at least one photovoltaic cell (16). [3] Structural composite panel (12) according to claim 1, wherein the structural reinforcement (24) is a structural fiber mixed with a non-structural 3D seam comprising at least one of the elements: polycarbonate, nylon, polyethylene or polypropylene to solidify the fiber and a preform. [4] Structural composite panel (12) according to claim 1, wherein the at least one photovoltaic cell (16) comprises at least one of the elements: monocrystalline silicon, polycrystalline silicon, a thin film or indium tin oxide. [5] Structural composite panel (12) according to claim 1, wherein the at least one photovoltaic cell (16) is arranged on a part of the first layer (14) which does not have structural reinforcement (24). [6] Structural composite panel (12) according to claim 1, wherein the at least one photovoltaic cell (16) is arranged on a part of the first layer (14) which has both a structural reinforcement (24) and no structural reinforcement (24). [7] Structural composite panel (12) according to claim 1, wherein the resin (22) comprises at least one of the elements: polycarbonate or acrylic.

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