Composite panel with photovoltaic module

Abstract

Composite disc with a photovoltaic module (4), manufactured by a process comprising at least the following steps a) Providing a stack of layers (1) comprising at least an outer pane (2), a first thermoplastic intermediate layer (3), a photovoltaic module (4), a second thermoplastic intermediate layer (5) and an inner pane (6), wherein the photovoltaic module (4) comprises at least one solar cell (7) and is arranged between the outer pane (2) and the inner pane (6), the first thermoplastic intermediate layer (3) is arranged between the outer pane (2) and the photovoltaic module (4), the second thermoplastic intermediate layer (5) is arranged between the photovoltaic module (4) and the inner pane (6), at least in certain areas between the photovoltaic module (4) and the first thermoplastic intermediate layer (3) and / or the second thermoplastic intermediate layer (5) a space for air passage is formed in such a way that a ventilation network (8) is formed, and the stack of layers (1) has at least one ventilation duct (9) extending from the ventilation network (8) to the surroundings; b) Arranging the stack of layers (1) in a vacuum bag or arranging a vacuum ring around the stack of layers (1); c) Heating the stack of layers (1) to a temperature between 30 °C and 70 °C; d) Venting the heated stack of layers (1) at a temperature between 30 °C and 70 °C; e) Gradual increase of the temperature to a temperature between 100 °C and 130 °C to form a vented pre-composite; f) Removal of the vacuum bag or vacuum ring; g) Lamination of the deaerated pre-composite in an autoclave, wherein the layer stack (1) additionally comprises a third thermoplastic intermediate layer (10) with a recess (11) which is arranged between the first thermoplastic intermediate layer (3) and the second thermoplastic intermediate layer (5) and surrounds the photovoltaic module (4) in a frame-like manner, wherein an air passage gap is formed between the photovoltaic module (4) and the third thermoplastic intermediate layer (10) and the ventilation network (8) encompasses the gap between the third thermoplastic intermediate layer (10) and the photovoltaic module (4). or wherein two strips of a fourth thermoplastic intermediate layer (12) are arranged side by side between the first thermoplastic intermediate layer (3) and the second thermoplastic intermediate layer (5) and a venting channel (9) is formed between the strips of the fourth thermoplastic intermediate layer (12), which extends from the venting channel network to a side edge of the layer stack (1) and / or wherein at least one vent channel (9) is formed by a recess (13) designed as a perforation in the first thermoplastic intermediate layer (3), which extends from the vent channel network (8) to a side edge of the layer stack (1) and / or at least one vent channel (9) is formed as a recess (13) designed as a perforation in the second thermoplastic intermediate layer (5), which extends from the vent channel network (8) to a side edge of the layer stack (1), and / or wherein at least one vent channel (9) is formed through a hole (14) in the inner disc (6) and the second thermoplastic intermediate layer (5) or through a hole (14) in the outer disc (2) and the first thermoplastic intermediate layer (3), which, when viewed through the layer stack (1), is located in an area where the vent channel network (8) is located, and in step b) the layer stack (1) is arranged in a vacuum bag.

Description

[0001] The invention relates to a composite disc with a photovoltaic module.

[0002] It is generally known that glazing can be equipped with photovoltaic components to generate electrical energy. For example, WO03028114A2 discloses an insulating glass unit with a photovoltaic module. Insulating glass units are used particularly as building glazing.

[0003] Glazing with photovoltaic components can also be of interest in the automotive sector, particularly as a vehicle roof window. The photovoltaic components can be used, for example, to charge the vehicle's battery or to power electrical consumers. This is gaining increasing importance, especially in connection with electric vehicles. EP1036683A2 discloses a vehicle roof window designed as a single pane of glass and equipped with a solar cell array on the interior side.

[0004] Vehicle roof windows are often designed as laminated windows, comprising an outer pane and an inner pane bonded together via a thermoplastic interlayer. In such laminated windows, photovoltaic components can be embedded in the interlayer, as is known, for example, from WO2013182398A1 and WO2013182399A1.

[0005] To manufacture vehicle roof panels with photovoltaic modules, the modules can be laminated either between a flexible film and a glass pane or between two glass panes. The arrangement between two glass panes is the preferred configuration, but also presents a challenge in terms of lamination.

[0006] Solar cells are generally very brittle and can easily break during the lamination process. Lamination can also create so-called microcracks in the solar cell, which weaken it. Vibrations in the vehicle and temperature fluctuations can cause these microcracks to develop into cell fractures, which in the worst case can damage the photovoltaic module.

[0007] Microcracks are not directly visible to the naked eye, but can be made visible using electroluminescence by connecting the photovoltaic module to an external power source. This causes the solar cell to emit infrared light, which can be detected by an infrared camera. Dark lines or shadows can indicate microcracks.

[0008] Composite sheets with photovoltaic modules are typically laminated using specialized tools called laminators. The stack to be laminated is heated in a vacuum chamber, eliminating any external forces acting upon it. Once the stack reaches a temperature of 110 °C and the interlayer is soft, mechanical forces are applied via a flexible membrane. The production of composite sheets with photovoltaic modules using laminators is described in EP1997614B1 and US6481482B1.

[0009] From a technical standpoint, such laminators are suitable for flat composite panels, as no special tooling is required. However, manufacturing curved composite panels with photovoltaic modules would necessitate a specific mold for each model to withstand the pressure of the membrane and prevent breakage of the glass panels. This would entail high tooling costs for the various model-specific molds. Furthermore, a large number of tools would be required to achieve short cycle times.

[0010] EP0605994A1 discloses a method for encapsulating photovoltaic cells in laminated glazing. The method comprises the following steps: providing a polymeric interlayer, making a portion of the main surface of the polymeric interlayer sticky by applying a solvent to that portion, adhering a photovoltaic cell to the sticky portion of the polymeric interlayer's surface, arranging the polymeric interlayer with the photovoltaic cell adhered to it between two glass panes, and laminating the glass panes and the polymeric interlayer with the photovoltaic cell adhered to it, thereby encapsulating the photovoltaic cell within the laminated glazing.

[0011] JP2002185027A discloses a solar cell encapsulation film. To prevent problems such as cell damage, venting defects, and film leakage during solar battery manufacturing, numerous recessed areas are embossed into the film surface. Additionally, connecting pathways are provided to link adjacent recessed areas. The recessed areas and connecting pathways are arranged in a uniform pattern with high periodicity on the film.

[0012] The present invention is based on the objective of providing an improved composite disc with a photovoltaic module.

[0013] The problem is solved according to the invention by a composite disk according to independent claim 1. Advantageous embodiments are set forth in the dependent claims.

[0014] Using electroluminescence methods, the inventors discovered that microcracks form during the venting phase when the stack of glass being vented is subjected to strong mechanical forces.

[0015] Standard lamination technologies for automotive glass are therefore less suitable for laminated glass with photovoltaic modules, especially curved laminated glass with photovoltaic modules, because the thermoplastic interlayers are too hard and exert mechanical forces on the solar cells of the photovoltaic module during the venting phase, leading to microcracks and cell breakage. Regardless of the type of interlayer used, a hard thermoplastic interlayer always causes localized mechanical forces on the solar cells of the photovoltaic module during venting, whereas a softer thermoplastic interlayer allows the forces to be distributed across the entire surface of the cell.In standard lamination technology, if the thermoplastic intermediate layers used are heated to soften them, the problem arises that venting is no longer possible because the overlapping thermoplastic intermediate layers stick together.

[0016] According to the invention, this problem can be solved by providing at least one venting channel in the layer stack to be vented, which closes automatically at higher temperatures after venting. This technique enables reliable venting at higher temperatures and prevents microcracks and cell breakage.

[0017] The composite disc according to the invention with a photovoltaic module is manufactured according to a method comprising at least the following steps: a) Providing a stack of layers comprising at least an outer pane, a first thermoplastic interlayer, a photovoltaic module, a second thermoplastic interlayer and an inner pane, b) Arranging the stack of layers in a vacuum bag or arranging a vacuum ring around the stack of layers, c) Heating the stack of layers to a temperature between 30 °C and 70 °C, d) Venting the heated stack of layers at a temperature between 30 °C and 70 °C, e) Gradual increase of the temperature to a temperature between 100 °C and 130 °C to form a vented pre-composite, f) Removing the vacuum bag or vacuum ring, g) Lamination of the deaerated pre-composite in an autoclave.

[0018] Step a) is the first step of the procedure. After step a), steps b) and c) are carried out in any order or simultaneously. Step d) follows, then step e), step f) follows step e), and step g) follows step f).

[0019] In the layer stack provided in step a), the photovoltaic module comprises at least one solar cell and is arranged between the outer and inner panes. The first thermoplastic intermediate layer is arranged between the outer pane and the photovoltaic module, and the second thermoplastic intermediate layer is arranged between the photovoltaic module and the inner pane. A gap for air passage is formed, at least partially, between the photovoltaic module and the first thermoplastic intermediate layer and / or the second thermoplastic intermediate layer, such that a ventilation network is formed. According to the invention, the layer stack has at least one ventilation channel extending from the ventilation network to the surroundings.

[0020] A venting channel within the meaning of the invention is defined as a structure permeable to gases, through which any air inclusions that may be present during the venting of the layer stack in step d) can escape along the venting channel.

[0021] In this context, the term "surroundings" refers to the area surrounding the stack of layers, that is, the areas immediately adjacent to the stack of layers.

[0022] The stack of layers has an outer surface and an inner surface as well as side edges, the side edges together forming a circumferential edge of the stack of layers.

[0023] As described above, in step c) the layer stack is heated to a temperature between 30 °C and 70 °C, preferably between 40 °C and 60 °C, and in step d) the heated layer stack is vented, also at a temperature between 30 °C and 70 °C, preferably between 40 °C and 60 °C. At temperatures between 30 °C and 70 °C, preferably between 40 °C and 60 °C, the thermoplastic interlayers of the layer stack are so soft that significantly reduced point mechanical forces act on the solar cells of the photovoltaic module, and the forces are distributed more evenly over the entire surface of the solar cells. For example, in step c) the layer stack is heated to a temperature of 45 °C, and the venting of the heated layer stack also takes place at 45 °C.It is understood that the temperature to which the layer stack is heated in step c) and the temperature at which the layer stack is vented in step d) do not necessarily have to be the same. The temperatures can also be different, provided that the respective temperatures are between 30 °C and 70 °C.

[0024] The heating of the layer stack preferably takes place in a preheating station and can be done, for example, using hot air or infrared radiators.

[0025] The venting of the heated layer stack in step d) is carried out at a vacuum preferably less than or equal to 0.3 bar, particularly preferably less than or equal to 0.2 bar, and most preferably less than or equal to 0.15 bar, for example, p = 0.1 bar. The pressure values ​​refer to absolute pressure, that is, the pressure relative to absolute vacuum with p = 0 bar. The venting is preferably carried out for a period of time greater than or equal to 8 minutes, for example, for a period of 30 minutes.

[0026] As described above, in step e) the temperature is gradually increased to between 100 °C and 130 °C to form a vented pre-composite. For example, the temperature is gradually increased to 115 °C. The negative pressure is maintained during the temperature increase. At such temperatures, the thermoplastic intermediate layers become so soft that they melt and flow largely into the venting network and the at least one venting channel, filling and sealing them.

[0027] It is understood that in step f) the vacuum bag or vacuum ring is vented before or during its removal.

[0028] The lamination of the vented pre-composite to form the composite panel with photovoltaic module according to the invention takes place in step g) in an autoclave, i.e., at elevated temperature and pressure. Suitable process parameters for laminating the vented pre-composite in an autoclave are known to those skilled in the art. For example, the lamination in the autoclave can be carried out at an elevated pressure of approximately 10 to 15 bar and temperatures of 130 to 145 °C for approximately 2 hours.

[0029] As described above, the photovoltaic module has at least one solar cell. It is understood that the photovoltaic module also includes necessary electrical connections such as connectors between the solar cells if more than one solar cell is present, or busbars.

[0030] A gap belonging to the ventilation network for air passage can be formed in particular along one or more edges of a solar cell of the photovoltaic module and / or along connectors or collector conductors of the photovoltaic module.

[0031] In a particularly preferred embodiment, the photovoltaic module has at least two solar cells and an air passage space is formed between each pair of solar cells, which is also included in the ventilation network.

[0032] The invention therefore also relates to a composite disc with a photovoltaic module manufactured according to a method comprising at least the following steps. a) Providing a stack of layers comprising at least an outer pane, a first thermoplastic intermediate layer, a photovoltaic module, a second thermoplastic intermediate layer and an inner pane, wherein the photovoltaic module comprises at least two solar cells and at least in certain areas between the photovoltaic module and the first thermoplastic intermediate layer and / or the second thermoplastic intermediate layer as well as between each pair of adjacent solar cells, a space for air passage is formed in such a way that a ventilation network is formed, and the stack of layers has at least one ventilation channel leading from the ventilation network to the environment; b) Arranging the stack of layers in a vacuum bag or arranging a vacuum ring around the stack of layers, c) Heating the stack of layers to a temperature between 30 °C and 70 °C, d) Venting the heated stack of layers at a temperature between 30 °C and 70 °C, e) Gradual increase of the temperature to a temperature between 100 °C and 130 °C to form a vented pre-composite, f) Removing the vacuum bag or vacuum ring, g) Lamination of the vented pre-composite.

[0033] The air gap between two adjacent solar cells has a width of between 1 mm and 100 mm, preferably between 1 mm and 10 mm, and most preferably between 2 mm and 5 mm. In this context, the width of the gap refers to the shortest distance between two adjacent solar cells. If the photovoltaic module has more than two solar cells, the air gaps between each pair of solar cells need not be the same width, but can be of different sizes, depending on how the solar cells are arranged in the photovoltaic module. Individual sections of the ventilation network between the solar cells can therefore have different widths.

[0034] In a preferred embodiment, the layer stack additionally comprises a third thermoplastic intermediate layer, which is arranged between the first and second thermoplastic intermediate layers and has a recess in which the photovoltaic module is received. Thus, in this embodiment, the third thermoplastic intermediate layer surrounds the photovoltaic module in a frame-like manner. Preferably, the outer dimensions (length and width) of the recess correspond substantially to the outer dimensions of the photovoltaic module; that is, the recess and the photovoltaic module have essentially the same geometry.Preferably, the recess is larger in dimensions (length and width) than the photovoltaic module, so that an air gap is formed between the photovoltaic module and the third thermoplastic intermediate layer, and the ventilation network includes the gap between the third thermoplastic intermediate layer and the photovoltaic module. The size of the recess in the third thermoplastic intermediate layer is particularly preferably dimensioned such that the distance between the photovoltaic module and the third thermoplastic intermediate layer is a maximum of 20 mm, and in particular, the distance is between 1 mm and 6 mm.

[0035] The at least one vent channel can be configured in various ways. It can be subtractively or additively formed. A subtractively formed vent channel can be created by a recess in one of the thermoplastic intermediate layers, extending from the vent network to a side edge of the layer stack. Alternatively, a subtractively formed vent channel can be created by a hole in the inner disc and the second thermoplastic intermediate layer, or by a hole in the outer disc and the first thermoplastic intermediate layer, which, when viewed through the layer stack, is located in an area where the vent network is situated.An additively applied venting channel can be formed by two adjacent strips of a fourth thermoplastic intermediate layer, wherein the venting channel is formed between the two strips and extends from the venting channel network to a side edge of the layer stack.

[0036] It is understood that if the stack of layers has two or more ventilation channels, these may be designed in the same way or in different ways.

[0037] In one embodiment, the layer stack additionally comprises a third thermoplastic intermediate layer with a recess, which is arranged between the first and second thermoplastic intermediate layers and surrounds the photovoltaic module in a frame-like manner. At least one ventilation channel is formed by a recess in the third thermoplastic intermediate layer, which extends from the ventilation channel network to a side edge of the layer stack. As described above, the recess in the third thermoplastic intermediate layer is preferably larger than the photovoltaic module, so that a gap for air passage is formed between the photovoltaic module and the third thermoplastic intermediate layer, and the ventilation channel network includes the gap between the third thermoplastic intermediate layer and the photovoltaic module.

[0038] The recess in the third thermoplastic intermediate layer is preferably between 1 mm and 5 mm wide, and particularly preferably between 2 mm and 3 mm wide. It is understood that the length of the recess corresponds to the path from the venting network to a side edge of the layer stack.

[0039] The recess in the third thermoplastic intermediate layer is preferably designed as a perforation, i.e., the recess extends over the entire thickness of the third thermoplastic intermediate layer. The thickness of the recess in the third thermoplastic intermediate layer thus preferably corresponds to the thickness of the third thermoplastic intermediate layer. Consequently, with a perforation-designed recess in the third thermoplastic intermediate layer, no material of the third thermoplastic intermediate layer is present in the layer stack in the region of the recess.

[0040] In a further embodiment, the stack of layers additionally has a third thermoplastic intermediate layer with a recess, which is arranged between the first thermoplastic intermediate layer and the second thermoplastic intermediate layer and surrounds the photovoltaic module in a frame-like manner, and between the first thermoplastic intermediate layer and the third thermoplastic intermediate layer, two strips of a fourth thermoplastic intermediate layer are arranged side by side, and a vent channel is formed between the strips of the fourth thermoplastic intermediate layer and extends from the vent channel network to a side edge of the stack of layers.As described above, the recess in the third thermoplastic intermediate layer is preferably larger than the photovoltaic module, so that an air gap is formed between the photovoltaic module and the third thermoplastic intermediate layer, and the ventilation network includes the gap between the third thermoplastic intermediate layer and the photovoltaic module.

[0041] In a further embodiment, the stack of layers additionally has a third thermoplastic intermediate layer with a recess, which is arranged between the first thermoplastic intermediate layer and the second thermoplastic intermediate layer and surrounds the photovoltaic module in a frame-like manner, and between the second thermoplastic intermediate layer and the third thermoplastic intermediate layer, two strips of a fourth thermoplastic intermediate layer are arranged side by side, and a vent channel is formed between the strips of the fourth thermoplastic intermediate layer and extends from the vent channel network to a side edge of the stack of layers.As described above, the recess in the third thermoplastic intermediate layer is preferably larger than the photovoltaic module, so that an air gap is formed between the photovoltaic module and the third thermoplastic intermediate layer, and the ventilation network includes the gap between the third thermoplastic intermediate layer and the photovoltaic module.

[0042] In a further embodiment, two strips of a fourth thermoplastic intermediate layer are arranged side by side between the first thermoplastic intermediate layer and the second thermoplastic intermediate layer, and a venting channel is formed between the strips of the fourth thermoplastic intermediate layer, extending from the venting channel network to a side edge of the layer stack. In this embodiment, the layer stack does not have a third thermoplastic intermediate layer.

[0043] The strips of a fourth thermoplastic intermediate layer, for example, have a width of 3 mm and a thickness of 0.38 mm. It is understood that the length of the strips corresponds to the distance from the venting network to a side edge of the layer stack. The strips of the fourth thermoplastic intermediate layer are preferably arranged substantially parallel to each other, and the shortest distance between the two strips is preferably between 1 mm and 5 mm, more preferably between 2 mm and 3 mm.

[0044] It is understood that in further embodiments, more than two strips of a fourth thermoplastic intermediate layer can be arranged between the first thermoplastic intermediate layer and the second thermoplastic intermediate layer, between the first thermoplastic intermediate layer and the third thermoplastic intermediate layer, or between the second thermoplastic intermediate layer and the third thermoplastic intermediate layer, wherein a venting channel is formed between two adjacent strips of the fourth thermoplastic intermediate layer, extending from the venting channel network to a side edge of the layer stack.

[0045] In a further embodiment, at least one vent channel is formed by a recess in the first thermoplastic intermediate layer, which extends from the vent channel network to a side edge of the layer stack. Optionally, in this embodiment, the layer stack can additionally have a third thermoplastic intermediate layer with a recess, wherein the third thermoplastic intermediate layer is arranged between the first thermoplastic intermediate layer and the second thermoplastic intermediate layer and surrounds the photovoltaic module in a frame-like manner.

[0046] The recess in the first thermoplastic intermediate layer is preferably between 1 mm and 5 mm wide, and particularly preferably between 2 mm and 3 mm wide. It is understood that the length of the recess corresponds to the path from the venting network to a side edge of the layer stack.

[0047] The recess in the first thermoplastic intermediate layer is preferably designed as a perforation, i.e., the recess extends over the entire thickness of the first thermoplastic intermediate layer. The thickness of the recess in the first thermoplastic intermediate layer thus preferably corresponds to the thickness of the first thermoplastic intermediate layer. Consequently, with a perforation-designed recess in the first thermoplastic intermediate layer, no material from the first thermoplastic intermediate layer is present in the layer stack in the region of the recess.

[0048] In a further embodiment, at least one vent channel is formed by a recess in the second thermoplastic intermediate layer, which extends from the vent channel network to a side edge of the layer stack. Optionally, in this embodiment, the layer stack can additionally have a third thermoplastic intermediate layer with a recess, wherein the third thermoplastic intermediate layer is arranged between the first thermoplastic intermediate layer and the second thermoplastic intermediate layer and surrounds the photovoltaic module in a frame-like manner.

[0049] The recess in the second thermoplastic intermediate layer is preferably between 1 mm and 5 mm wide, and particularly preferably between 2 mm and 3 mm wide. It is understood that the length of the recess corresponds to the path from the venting network to a side edge of the layer stack.

[0050] The recess in the second thermoplastic intermediate layer is preferably designed as a perforation, i.e., the recess extends over the entire thickness of the second thermoplastic intermediate layer. The thickness of the recess in the second thermoplastic intermediate layer thus preferably corresponds to the thickness of the second thermoplastic intermediate layer. Consequently, with a perforation-designed recess in the second thermoplastic intermediate layer, no material of the second thermoplastic intermediate layer is present in the layer stack in the region of the recess.

[0051] A venting channel, formed as a recess in the first, second, or third thermoplastic intermediate layer, preferably runs substantially perpendicular to the side edge of the layer stack nearest the transition from the venting channel to the venting network. Such a venting channel can be linear, curved, or meandering, with even more complex shapes preferably having a main direction perpendicular to the nearest side edge of the layer stack.

[0052] It is understood that the recess for a vent channel, designed as a cutout in the first, second, or third thermoplastic intermediate layer, is incorporated into the first, second, or third thermoplastic intermediate layer after or during the process of cutting it from a thermoplastic intermediate layer supplied as roll stock to a size suitable for the layer stack. The recess is therefore not formed during the production of the thermoplastic intermediate layer as roll stock. In this way, the desired positioning of the vent channel, designed as a cutout in the first, second, or third thermoplastic intermediate layer, within the layer stack can be ensured. The vent channel is thus formed precisely at the desired location.

[0053] In a further embodiment, at least one ventilation channel is formed by a hole in the inner pane and the second thermoplastic intermediate layer, or by a hole in the outer pane and the first thermoplastic intermediate layer. When viewed through the layer stack, the hole is located in an area where the ventilation network is situated. It is understood that in this embodiment, in step b), the layer stack is arranged in a vacuum bag. Preferably, in embodiments where the ventilation channel is formed by a hole, the hole is located in the inner pane and the second thermoplastic intermediate layer. Furthermore, the hole is preferably located in an area that, after the composite pane is installed in a vehicle, is concealed by the vehicle body or its attachments. The diameter of the hole is preferably between 1 mm and 5 mm, and particularly preferably between 2 mm and 3 mm.

[0054] In embodiments in which a vent channel is formed as a hole in the inner disc and the second thermoplastic intermediate layer or as a hole in the outer disc and the first thermoplastic intermediate layer, the method preferably comprises, after step g), an additional process step in which the hole in the inner disc or the outer disc is closed.

[0055] The invention therefore also includes a composite disc with a photovoltaic module manufactured according to a method comprising at least the following steps a) Providing a stack of layers comprising at least an outer pane, a first thermoplastic interlayer, a photovoltaic module, a second thermoplastic interlayer and an inner pane, wherein the photovoltaic module comprises at least one solar cell and is arranged between the outer pane and the inner pane, the first thermoplastic intermediate layer is positioned between the outer pane and the photovoltaic module, the second thermoplastic intermediate layer is arranged between the photovoltaic module and the inner pane, at least in certain areas between the photovoltaic module and the first thermoplastic intermediate layer and / or the second thermoplastic intermediate layer, a space for air passage is formed in such a way that a ventilation network is formed, wherein the layer stack has at least one ventilation channel leading from the ventilation network to the environment, and wherein optionally a third thermoplastic intermediate layer is arranged between the first thermoplastic intermediate layer and the second thermoplastic intermediate layer, which surrounds the photovoltaic module in a frame-like manner, wherein an air gap is formed between the photovoltaic module and the third thermoplastic intermediate layer and the ventilation network includes the gap between the third thermoplastic intermediate layer and the photovoltaic module; b) Arranging the stack of layers in a vacuum bag or arranging a vacuum ring around the stack of layers; c) Heating the stack of layers to a temperature between 30 °C and 70 °C; d) Venting the heated stack of layers at a temperature between 30 °C and 70 °C; e) Gradual increase of the temperature to a temperature between 100 °C and 130 °C to form a vented pre-composite; f) Removal of the vacuum bag or vacuum ring; g) Lamination of the deaerated pre-composite in an autoclave, where between the first thermoplastic intermediate layer and the second thermoplastic intermediate layer or between the first thermoplastic intermediate layer and the optional third thermoplastic intermediate layer or between the second thermoplastic intermediate layer and the optional third thermoplastic intermediate layer, two strips of a fourth thermoplastic intermediate layer are arranged side by side and a venting channel is formed between the strips of the fourth thermoplastic intermediate layer, which extends from the venting channel network to a side edge of the layer stack, and / or wherein at least one vent channel is formed by a recess designed as a perforation in the first thermoplastic intermediate layer, which extends from the vent channel network to a side edge of the layer stack and / or at least one vent channel is formed as a recess designed as a perforation in the second thermoplastic intermediate layer, which extends from the vent channel network to a side edge of the layer stack, and / or at least one vent channel is designed as a recess in the third thermoplastic intermediate layer, which extends from the vent channel network to a side edge of the layer stack, and / or wherein at least one ventilation channel passes through a hole in the inner pane and the second thermoplastic intermediate layer or through a hole in the outer pane and the first thermoplastic intermediate layer is formed, which, when viewed through the stack of layers, is located in an area where the venting network is located, and in step b) the stack of layers is arranged in a vacuum bag.

[0056] The method can also be modified such that the at least one vent channel is formed by a pipe with a diameter of preferably 1 mm, which is arranged between the outer and inner discs and extends from the vent network to the environment. In such a modified method, the pipe is removed during the gradual increase of the temperature to a temperature between 100 °C and 130 °C to form a vented pre-composite.

[0057] The outer and inner panes are preferably made of glass, particularly preferably of soda-lime glass, as is common for window panes. However, one or both panes can also be made of other types of glass, such as quartz glass, borosilicate glass, or aluminosilicate glass.

[0058] The thicknesses of the outer disc and the inner disc are preferably from 1.0 mm to 12 mm, particularly preferably from 0.5 mm to 5 mm, and most preferably from 1 mm to 3 mm, for example 2.1 mm or 1.6 mm, independently of each other.

[0059] The outer pane and the inner pane can optionally be thermally or chemically prestressed, partially prestressed or not prestressed independently of each other.

[0060] In a preferred embodiment, the outer and inner panes are curved in one or more spatial directions, as is common for automotive windows, particularly roof windows. Typical radii of curvature range from approximately 50 mm to approximately 1200 mm. The radius of curvature need not be constant across the entire laminated pane. Areas with varying degrees of curvature are possible. Flat and curved areas are also possible. The outer and inner panes can also be flat, for example, if the laminated pane is intended for use in buses, trains, tractors, or as building glazing.

[0061] The surface area of ​​the composite panel can vary widely and thus be perfectly adapted to the requirements of individual cases. For example, the surface area of ​​the composite panel can range from 100 cm². 2 up to 5 m 2 to be, preferably 0.5 m 2 up to 3 m 2The composite pane is preferably a roof pane.

[0062] The area of ​​the photovoltaic module preferably comprises 50% to 100% of the area of ​​the composite panel, for example, 50% to 90%. This is particularly advantageous with regard to the performance of the integrated photovoltaic module and a uniform appearance of the composite panel. The area of ​​the photovoltaic module can, for example, range from 0.1 m². 2 up to 5 m 2 preferably 0.5 m 2 up to 2 m 2 be.

[0063] The first thermoplastic intermediate layer, the second thermoplastic intermediate layer, the optionally present third thermoplastic intermediate layer and / or the optionally present fourth thermoplastic intermediate layer contain or consist independently of each other of a thermoplastic polymer, preferably polyvinyl butyral (PVB), ethylene vinyl acetate (EVA) and / or thermoplastic polyolefin (TPO).

[0064] The first thermoplastic intermediate layer and the second thermoplastic intermediate layer preferably have a thickness of 0.2 mm to 2 mm, more preferably 0.3 mm to 1 mm, and particularly 0.3 mm to 0.5 mm, for example 0.38 mm. The thickness of the first thermoplastic intermediate layer and the thickness of the second thermoplastic intermediate layer can also each be, for example, 0.76 mm.

[0065] The optional third thermoplastic interlayer can, for example, be 0.38 mm thick. Preferably, the thickness of the optional third thermoplastic interlayer corresponds to the thickness of the photovoltaic module.

[0066] A photovoltaic module, as defined in the invention, is a component for generating electrical energy or current by means of the photovoltaic effect. The photovoltaic module is handled as a single component and preferably has only two electrical connections (two electrical poles, i.e., "positive and negative poles") through which the component as a whole is electrically connected. The photovoltaic module comprises at least one solar cell, preferably a plurality of interconnected or electrically connected solar cells. The solar cells can be connected in series or in parallel, or there can be groups of solar cells connected in series that are connected in parallel, or groups of solar cells connected in parallel that are connected in series. A series connection of all solar cells is preferred.The photovoltaic module can also be referred to as a photovoltaic module or solar module. For the purposes of the invention, a solar cell is the smallest possible photovoltaic unit, comprising a single photovoltaically active absorber layer between a single front electrode and a single back electrode. The solar cell is not structurally subdivided further. The solar cell can also be referred to as a photovoltaic cell.

[0067] The solar cells of the photovoltaic module are capable of directly converting sunlight into electrical energy. Each solar cell has a photovoltaically active absorber layer between a front electrode and a back electrode. The front electrode faces the outer pane of the composite panel, and the back electrode faces the inner pane. The electrodes are primarily surface electrodes that cover the entire absorber layer. When sunlight is absorbed, free charge carriers are generated in the absorber layer (the photovoltaic effect, a special case of the internal photoelectric effect). These free charge carriers are then transferred via the electrodes to generate electrical energy or an electric current. The absorber layer often contains dopants to optimize the transport of the charge carriers to the electrodes.

[0068] In principle, all types of solar cells can be used within the scope of the present invention. There are no restrictions to specific solar cells. In particular: - Thin-film cells or thick-film cells can be used; in a thin-film cell, the absorber layer is a thin layer with a thickness of, for example, 0.5 µm to 3 µm; in thick-film cells, the absorber layer has a greater thickness (for example, 20 µm to 500 µm); - any photovoltaically active material can be used for the absorber layer, for example inorganic semiconductors (such as silicon, cadmium telluride, gallium arsenide, indium gallium arsenide, indium gallium phosphide, CI(G)S chalcopyrite semiconductors or combinations thereof) or organic conjugated polymers, organic conjugated oligomers or organic dyes; - the crystal structure of the absorber layer can be monocrystalline, polycrystalline or amorphous.

[0069] Thick-film cells can, for example, have an absorber layer based on monocrystalline or polycrystalline silicon. Thin-film cells can, for example, have an absorber layer based on amorphous or polycrystalline (especially microcrystalline) silicon, on gallium arsenide, on cadmium telluride, or on organic conjugated polymers. Thin-film cells can also have a chalcopyrite semiconductor such as a copper-indium-sulfur / selenium compound (CIS; for example, CuInSe₂) or a copper-indium-gallium-sulfur / selenium compound (CIGS; for example, Cu(InGa)(SSe)₂).

[0070] The method is particularly advantageous for thick-film cells because these are typically more fragile than thin-film cells.

[0071] The front and back electrodes can be designed, for example, as thin conductive or semiconducting layers with thicknesses preferably ranging from 50 nm to 2 µm. These layers can contain, for example, metals such as silver, gold, copper, molybdenum, titanium, tungsten, nickel, chromium, tantalum, aluminum-doped zinc oxide, or transparent conductive oxides such as indium tin oxide. Alternatively, the front and / or back electrode can be designed, for example, as a mesh of thin wires containing, for example, aluminum, copper, silver, and / or gold. At least the front electrode is transparent to allow sunlight to penetrate the absorber layer. The electrodes can be designed as single layers or as stacks of multiple layers.

[0072] In addition to the absorber layer and the electrodes, the solar cell can of course include other individual layers known to those skilled in the art, for example a buffer layer for adjusting the electronic properties between the absorber layer and an electrode layer or diffusion barrier layers.

[0073] Before or during the stacking of the layers, the photovoltaic module is provided with the necessary electrical connections, with electrical conductors extending beyond the side edge of the layer stack, by means of which the photovoltaic module can later be electrically contacted, for example for connection to an electrical system, a battery or one or more individual electrical consumers.

[0074] The outer pane has (at least) one transparent area through which sunlight can pass and excite the photovoltaic module. This transparent area of ​​the outer pane therefore defines an active area of ​​the laminated glass. The photovoltaic module is located (at least partially, in particular mostly or even completely) within this transparent area.

[0075] The outer pane can be entirely transparent. Alternatively, it can have an opaque masking area that prevents sunlight from passing through and defines a masking zone for the laminated glass. The active area then corresponds to the laminated glass minus the masking zone. Such masking zones are common in vehicle windows. They are typically created by an opaque printed coating on the surface of the outer pane facing the photovoltaic module. An enamel printing paste, containing glass frits and a pigment, particularly black pigment, is printed onto the surface, for example, using a screen printing process, and then fired. The masking zone typically encompasses a surrounding edge of the outer pane and is thus frame-like.The masking area can also include other areas, which are designed, for example, as a kind of cross bracing of the frame-like edge area.

[0076] Alternatively, a masking area can also be formed by making the first thermoplastic intermediate layer opaque in certain areas.

[0077] It is understood that, in addition to a transparent area where sunlight can pass through the outer pane and excite a photovoltaic module located in this area, the composite pane may also have other transparent areas where, when viewed through the composite pane, the photovoltaic module is not located.

[0078] In some embodiments, the inner pane and / or the second thermoplastic intermediate layer can be tinted or colored, at least in certain areas. The outer pane and / or the second thermoplastic intermediate layer can, for example, be tinted or colored in a circumferential edge region. The coloring or tinting can also be applied across the entire surface and, in particular, can be designed such that the photovoltaic module is not visible or only partially visible to an observer when looking at the inner pane.

[0079] In one embodiment, one of the surfaces of the outer pane is provided with an opaque covering print in a circumferential edge region, and / or one of the surfaces of the inner pane is provided with an opaque covering print in a circumferential edge region. However, it is also possible that one of the surfaces of the inner pane is provided with an opaque covering print not only in a circumferential edge region but across its entire surface, thus rendering the photovoltaic module invisible to an observer when looking at the inner pane. Preferably, the opaque covering print is arranged on the surface of the inner pane facing away from the photovoltaic module.

[0080] As described above, the layer stack according to the invention has at least one ventilation channel extending from the ventilation network to the environment. In a particularly preferred embodiment of the method, the layer stack has at least two ventilation channels extending from the ventilation network to the environment. Preferably, when at least two ventilation channels are present, they are arranged on opposite sides of the layer stack. Consequently, when at least two ventilation channels are formed as recesses in the first intermediate layer, the second intermediate layer, or the third intermediate layer, preferably one of the ventilation channels extends from the ventilation network to a first side edge of the layer stack, and another of the ventilation channels extends from the ventilation network to a second side edge of the layer stack, with the first side edge being opposite the second side edge.

[0081] In a preferred embodiment, the layer stack has a maximum of eight, particularly preferably a maximum of four, ventilation channels extending from the ventilation network to the environment.

[0082] In a preferred embodiment, the outer pane has a lower iron content than the inner pane. A low-iron outer pane is particularly advantageous with regard to the transmission of sunlight through the outer pane. Particularly preferably, the outer pane has an iron content of less than 0.05% iron oxide by weight, and more preferably less than 0.03% iron oxide by weight.

[0083] During the process for manufacturing the composite disc according to the invention, the thermoplastic intermediate layers melt as described above, and the ventilation channels and the ventilation network are largely filled with the thermoplastic layers. It is not discernible to the naked eye that the layer stack used in the process had a ventilation network and at least one ventilation channel in the composite disc according to the invention. However, in the composite disc produced according to the invention, the at least one ventilation channel and the ventilation network can be visualized in transmission by means of shadow projection onto a screen, with the projector located at a great distance, for example 8 m from the projection surface, and the composite disc located near, for example 50 cm, the projection surface.

[0084] A composite pane according to the invention can be used as a window pane in means of transport for land, air, or water traffic. The composite pane can be used, for example, as a windshield, side window, rear window, or roof window. The vehicle window is particularly preferably used as a vehicle roof window, especially as a roof window of a passenger car or truck.

[0085] The various embodiments of the invention can be implemented individually or in any combination. In particular, the features mentioned above and explained below can be used not only in the combinations specified, but also in other combinations or individually, without departing from the scope of the present invention.

[0086] The invention is explained in more detail below with reference to the drawings. The drawings are schematic representations and not to scale. The drawings do not limit the invention in any way.

[0087] They show: Fig. 1 a flowchart of a process by which a composite disk according to the invention is produced, Fig. 2 a top view of an embodiment of a layer stack, Fig. 3 a cross-section through the in the Fig. 2 layer stacks shown, Fig. 4 a top view of another embodiment of a layer stack, Fig. 5 a top view of another embodiment of a layer stack, Fig. 6 a top view of another embodiment of a layer stack, Fig. 7 a top view of another embodiment of a layer stack, Fig. 8 a top view of another embodiment of a layer stack, Fig. 9 a top view of another embodiment of a layer stack, Fig. 10 a top view of another embodiment of a layer stack, Fig. 11 a top view of another embodiment of a layer stack, Fig. 12 a top view of another embodiment of a layer stack, Fig. 13 a top view of another embodiment of a layer stack, Fig. 14 a top view of another embodiment of a layer stack, Fig. 15 an exploded view of the in the Fig. 2 and the Fig. 3 embodiment of a layer stack shown, Fig. 16 an exploded view of the in the Fig. 4 embodiment of a layer stack shown, Fig. 17 an exploded view of the in the Fig. 5 embodiment of a layer stack shown, Fig. 18 an exploded view of the in the Fig. 6 embodiment of a layer stack shown, Fig. 19 an exploded view of the in the Fig. 7 embodiment of a layer stack shown, Fig. 20 an exploded view of the in the Fig. 8 embodiment of a layer stack shown, Fig. 21 an exploded view of the in the Fig. 9 embodiment of a layer stack shown, Fig. 22 an exploded view of the in the Fig. 10 embodiment of a layer stack shown, Fig. 23 an exploded view of the in the Fig. 11 embodiment of a layer stack shown, Fig. 24 an exploded view of the in the Fig. 12 embodiment of a layer stack shown, Fig. 25 an exploded view of the in the Fig. 13 embodiment of a layer stack shown, Fig. 26 an exploded view of the in the Fig. 14 embodiment of a layer stack shown, Fig. 27 a top view of another embodiment of a layer stack, and Fig. 28 a top view of another embodiment of a layer stack.

[0088] In the Fig. Figure 1 shows a flowchart of a process by which the composite disc according to the invention is manufactured. In step a) of the process, a stack of layers is provided. The stack of layers comprises at least one outer disc, a first thermoplastic intermediate layer, a photovoltaic module, a second thermoplastic intermediate layer, and an inner disc. The photovoltaic module comprises at least one solar cell and is arranged between the outer disc and the inner disc. The first thermoplastic intermediate layer is arranged between the outer disc and the photovoltaic module. The second thermoplastic intermediate layer is arranged between the photovoltaic module and the inner disc. At least in certain areas between the photovoltaic module and the first thermoplastic intermediate layer and / or the second thermoplastic intermediate layer, a gap for air passage is formed such that a ventilation network is created.Furthermore, the layer stack has at least one venting channel leading from the venting network to the environment. In the subsequent step b) of the process, the layer stack is placed in a vacuum bag or, alternatively, a vacuum ring is placed around the layer stack. In step c) of the process, the layer stack is heated to a temperature between 30 °C and 70 °C. Step c) can be performed after step b) or simultaneously. Alternatively, step c) can also be performed before step b). In the subsequent step d) of the process, the heated layer stack is vented at a temperature between 30 °C and 70 °C. In the subsequent step e), the temperature is gradually increased to a temperature between 100 °C and 130 °C to form a vented pre-composite.In the following step f) the vacuum bag or vacuum ring is removed and in the following step g) the vented pre-composite is laminated in an autoclave, thereby obtaining a composite disk according to the invention with a photovoltaic module.

[0089] Fig. Figure 2 shows a top view of an embodiment of a layer stack 1, as it may be after step a) of the method and in Fig. 3 is the cross-section through the in the Fig. The layer stack shown in the 2 is located along the section line A'-A. Fig. 15 is the one in the Fig. 2 and the Fig. 3. The embodiment of the layer stack 1 is shown as an exploded view.

[0090] In the Fig. 2, Fig. 3 and Fig. In the embodiment shown in Figure 15, the layer stack 1 comprises an outer pane 2, a first thermoplastic intermediate layer 3, a photovoltaic module 4, a second thermoplastic intermediate layer 5, and an inner pane 6. The photovoltaic module 4 is arranged between the outer pane 2 and the inner pane 6, the first thermoplastic intermediate layer 3 is arranged between the outer pane 2 and the photovoltaic module 4, and the second thermoplastic intermediate layer 5 is arranged between the inner pane 6 and the photovoltaic module 4.

[0091] The outer pane 2 and the inner pane 6 are made of soda-lime glass, for example. The outer pane 2 has a thickness of 2.1 mm, and the inner pane 6 also has a thickness of 2.1 mm. The outer pane 1 is installed facing the outside environment, while the inner pane 2 faces the vehicle interior.

[0092] The first thermoplastic intermediate layer 3 and the second thermoplastic intermediate layer 5, for example, consist of PVB and each have a thickness of 0.76 mm.

[0093] The photovoltaic module 4 comprises in the Fig. 2, Fig. 3 and Fig. In the embodiment shown in Figure 15, a solar cell 7 is formed. An air gap is provided between the photovoltaic module 4 and the first thermoplastic intermediate layer 3 and the second thermoplastic intermediate layer 5. This air gap is designed to form a ventilation network 8. In the embodiment shown in the Fig. 2 and Fig. In the embodiment shown in Figure 15, the ventilation network 8 has the form of a frame surrounding the photovoltaic module 4.

[0094] In the Fig. 2, Fig. 3 and Fig. In the embodiment shown in Figure 15, the second thermoplastic intermediate layer 5 has a recess 13 through which a vent channel 9 is formed, extending from the vent network 8 to a side edge. The vent channel 9 extends from the vent network 8 to the side edge and thus to the surroundings of the layer stack 1. In the embodiment shown in the Fig. 2, Fig. 3 and Fig. In the embodiment shown in Figure 15, the vent channel 9 runs linearly and essentially perpendicular to the side edge of the layer stack 1 nearest to the transition from the vent channel 9 to the vent network 8. The width of the recess 13 is, for example, 3 mm. The recess 13 is located in the Fig. 2, Fig. 3 and Fig. 15 shown embodiment designed as a penetration.

[0095] It is understood that the vent channel 9 can alternatively be formed as a recess 13 in the first thermoplastic intermediate layer 3 instead of as a recess 13 in the second thermoplastic intermediate layer 5.

[0096] Alternatively, in the layer stack 1, between the first thermoplastic intermediate layer 3 and the second thermoplastic intermediate layer 5, two strips of a fourth thermoplastic intermediate layer 12 can be arranged side by side, and the vent channel 9 can be formed between the strips of the fourth thermoplastic intermediate layer 12. Also alternatively, the vent channel 9 can be formed as a hole 14 in the inner disk 6 and the second thermoplastic intermediate layer 5, wherein the hole 14, when viewed through the layer stack 1, is located in an area where the vent network 8 is arranged.

[0097] Fig. Figure 4 shows a top view of another embodiment of a layer stack 1, as it may be after step a) of the method. Fig. 16 is the one in the Fig. The embodiment of layer stack 1 shown in Figure 4 is depicted as an exploded view. In the embodiment shown in the Fig. 4 and Fig. In the embodiment shown in Figure 16, the layer stack 1 comprises an outer pane 2, a first thermoplastic intermediate layer 3, a photovoltaic module 4, a second thermoplastic intermediate layer 5, and an inner pane 6. The photovoltaic module 4 is arranged between the outer pane 2 and the inner pane 6, the first thermoplastic intermediate layer 3 is arranged between the outer pane 2 and the photovoltaic module 4, and the second thermoplastic intermediate layer 5 is arranged between the inner pane 6 and the photovoltaic module 4.

[0098] The outer pane 2 and the inner pane 6 are made of soda-lime glass, for example. The outer pane 2 has a thickness of 2.1 mm, and the inner pane 6 also has a thickness of 2.1 mm. The outer pane 1 is installed facing the outside environment, while the inner pane 2 faces the vehicle interior.

[0099] The first thermoplastic intermediate layer 3 and the second thermoplastic intermediate layer 5, for example, consist of PVB and each have a thickness of 0.76 mm.

[0100] The photovoltaic module 4 comprises in the Fig. 4 and Fig. In the embodiment shown in Figure 16, nine solar cells 7 are provided, with an air gap formed between each pair of adjacent solar cells 7. Furthermore, an air gap is formed between the photovoltaic module 4 and the first thermoplastic intermediate layer 3 and the second thermoplastic intermediate layer 5. The air gaps are designed to form a ventilation network 8. In the embodiment shown in the Fig. 4 and Fig. In the embodiment shown in Figure 16, the ventilation network 8 has a grid structure with a surrounding frame. The gaps for air passage between two solar cells 7 have, for example, a width of 3 mm and 5 mm, respectively.

[0101] In the Fig. 4 and Fig. In the embodiment shown in Figure 16, the second thermoplastic intermediate layer 5 has a recess 13 through which a vent channel 9 is formed, extending from the vent network 8 to a side edge. The vent channel 9 extends from the vent network to the side edge and thus to the surroundings of the layer stack 1. In the embodiment shown in the Fig. 4 and Fig. In the embodiment shown in Figure 16, the vent channel 9 runs linearly and substantially perpendicular to the side edge of the layer stack 1 nearest to the transition from the vent channel 9 to the vent network 8. The width of the recess 13 is, for example, 3 mm. The recess 13 is located in the Fig. 4 and Fig. 16 shown embodiment designed as a penetration.

[0102] It is understood that the vent channel 9 can alternatively be formed as a recess 13 in the first thermoplastic intermediate layer 3 instead of as a recess 13 in the second thermoplastic intermediate layer 5.

[0103] Fig. Figure 5 shows a top view of another embodiment of a layer stack 1, as it may be after step a) of the method. Fig. 17 is the one in the Fig. The embodiment of layer stack 1 shown in Figure 5 is depicted as an exploded view.

[0104] The in the Fig. 5 and Fig. The embodiment of the layer stack 1 shown in Figure 17 differs from the one shown in the Fig. 4 and Fig. The difference shown in Figure 16 is only that the vent channel 9 is not formed as a recess 13 in the second thermoplastic intermediate layer 5, but rather that two strips of a fourth thermoplastic intermediate layer 12 are arranged side by side in the layer stack 1 between the first thermoplastic intermediate layer 3 and the second thermoplastic intermediate layer 5, and the vent channel 9 is formed between the strips of the fourth thermoplastic intermediate layer 12. The strips of a fourth thermoplastic intermediate layer 12 have, for example, a width of 3 mm and a thickness of 0.38 mm. It is understood that the length of the strips corresponds to the path length from the vent channel network 8 to the side edge of the layer stack 1. The strips of the fourth thermoplastic intermediate layer 12 are arranged essentially parallel to each other, and the shortest distance between the two strips is, for example, 3 mm.The fourth thermoplastic intermediate layer 12 consists, for example, of PVB.

[0105] Fig. Figure 6 shows a top view of another embodiment of a layer stack 1, as it may be after step a) of the method. Fig. 18 is the one in the Fig. The embodiment of layer stack 1 shown in Figure 6 is depicted as an exploded view.

[0106] The in the Fig. 6 and Fig. The embodiment of the layer stack 1 shown in Figure 18 differs from the one shown in the Fig. 4 and Fig. Figure 16 shows only that the vent channel 9 is not formed as a recess 13 in the second thermoplastic intermediate layer 5, but rather through a hole 14 in the inner disk 6 and the second thermoplastic intermediate layer 5, wherein the hole 14, when viewed through the layer stack 1, is located in an area where the vent network 8 is arranged. The hole 14 has, for example, a diameter of 3 mm.

[0107] It is understood that in this embodiment the layer stack 1 is arranged in a vacuum bag in step b) of the method.

[0108] Furthermore, it is understood that the hole 14 can also be formed in the outer disk 2 and the first thermoplastic intermediate layer 3 instead of in the inner disk 6 and the second thermoplastic intermediate layer 5, although this is not preferred.

[0109] Fig. Figure 7 shows a top view of another embodiment of a layer stack 1, as it may be after step a) of the method. Fig. 19 is the one in the Fig. The embodiment of layer stack 1 shown in Figure 7 is depicted as an exploded view.

[0110] In the Fig. 7 and Fig. In the embodiment shown in Figure 19, the layer stack 1 comprises an outer pane 2, a first thermoplastic intermediate layer 3, a photovoltaic module 4, a third thermoplastic intermediate layer 10, a second thermoplastic intermediate layer 5, and an inner pane 6. The photovoltaic module 4 is arranged between the outer pane 2 and the inner pane 6, the first thermoplastic intermediate layer 3 is arranged between the outer pane 2 and the photovoltaic module 4, and the second thermoplastic intermediate layer 5 is arranged between the inner pane 6 and the photovoltaic module 4. The third thermoplastic intermediate layer 10 is arranged between the first thermoplastic intermediate layer 3 and the second thermoplastic intermediate layer 5 and has a recess 11 into which the photovoltaic module 4 is received, such that the third thermoplastic intermediate layer 10 surrounds the photovoltaic module 4 in a frame-like manner.

[0111] The outer pane 2 and the inner pane 6 are made of soda-lime glass, for example. The outer pane 2 has a thickness of 2.1 mm, and the inner pane 6 also has a thickness of 2.1 mm. The outer pane 1 is installed facing the outside environment, while the inner pane 2 faces the vehicle interior.

[0112] The first thermoplastic interlayer 3 and the second thermoplastic interlayer 5, for example, consist of PVB and each have a thickness of 0.76 mm. The third thermoplastic interlayer 10, for example, consists of PVB and has a thickness of 0.38 mm. Preferably, the third thermoplastic interlayer 10 has a thickness corresponding to the thickness of the photovoltaic module 4.

[0113] The photovoltaic module 4 comprises in the Fig. 7 and Fig. In the embodiment shown in Figure 19, nine solar cells 7 are provided, with an air gap formed between each pair of adjacent solar cells 7. Furthermore, an air gap is formed between the photovoltaic module 4 and the first thermoplastic intermediate layer 3 and the second thermoplastic intermediate layer 5. The air gaps are designed to form a ventilation network 8. In the embodiment shown in the Fig. 7 and Fig. In the embodiment shown in Figure 19, the recess 11 in the third thermoplastic intermediate layer 10 is larger than the photovoltaic module 4, so that an air gap is formed between the photovoltaic module 4 and the third thermoplastic intermediate layer 10, and the ventilation network 8 includes the gap between the third thermoplastic intermediate layer 10 and the photovoltaic module 4. Fig. 7 and Fig. In the embodiment shown in Figure 19, the ventilation network 8 thus has a grid structure with a surrounding frame. The gaps for air passage between two solar cells 7, for example, have a width of 3 mm and 5 mm, respectively.

[0114] In the Fig. 7 and Fig. In the embodiment shown in Figure 19, the third thermoplastic intermediate layer 10 has a recess 13 through which a vent channel 9 is formed, extending from the vent network 8 to a side edge. The vent channel 9 extends from the vent network 8 to the side edge and thus to the surroundings of the layer stack 1. In the embodiment shown in the Fig. 7 and Fig. In the embodiment shown in Figure 19, the vent channel 9 runs linearly and essentially perpendicular to the side edge of the layer stack 1 nearest to the transition from the vent channel 9 to the vent network 8. The width of the recess 13 is, for example, 3 mm. The recess 13 is located in the Fig. 7 and Fig. The embodiment shown in 19 is designed in the form of an opening.

[0115] Fig. Figure 8 shows a top view of another embodiment of a layer stack 1, as it may be after step a) of the method. Fig. 20 is the one in the Fig. The embodiment of layer stack 1 shown in Figure 8 is depicted as an exploded view.

[0116] The in the Fig. 8 and Fig. The embodiment of the layer stack 1 shown in Figure 20 differs from the one shown in the Fig. 7 and Fig. 19 shown only insofar as the vent channel 9 is not formed as a recess 13 in the third thermoplastic intermediate layer 10, but as a recess 13 in the second thermoplastic intermediate layer 5.

[0117] It is understood that the vent channel 9 can alternatively be formed as a recess 13 in the first thermoplastic intermediate layer 3 instead of as a recess 13 in the second thermoplastic intermediate layer 5.

[0118] Fig. Figure 9 shows a top view of another embodiment of a layer stack 1, as it may be after step a) of the method. Fig. 21 is the one in the Fig. The embodiment of layer stack 1 shown in Figure 9 is depicted as an exploded view.

[0119] The in the Fig. 9 and Fig. The embodiment of the layer stack 1 shown in Figure 21 differs from the one shown in the Fig. 7 and Fig. The difference shown in Figure 19 is only that the vent channel 9 is not formed as a recess 13 in the third thermoplastic intermediate layer 10, but rather that two strips of a fourth thermoplastic intermediate layer 12 are arranged side by side in the layer stack 1 between the third thermoplastic intermediate layer 10 and the second thermoplastic intermediate layer 5, and the vent channel 9 is formed between the strips of the fourth thermoplastic intermediate layer 12. The strips of a fourth thermoplastic intermediate layer 12 have, for example, a width of 3 mm and a thickness of 0.38 mm. It is understood that the length of the strips corresponds to the path length from the vent channel network 8 to the side edge of the layer stack 1. The strips of the fourth thermoplastic intermediate layer 12 are arranged essentially parallel to each other, and the shortest distance between the two strips is, for example, 3 mm.The fourth thermoplastic intermediate layer 12 consists, for example, of PVB.

[0120] It is understood that both strips of the fourth thermoplastic intermediate layer 12 can alternatively be arranged between the third thermoplastic intermediate layer 10 and the first thermoplastic intermediate layer 3 instead of between the third thermoplastic intermediate layer 10 and the second thermoplastic intermediate layer 5, so that the vent channel 9 is arranged between the first thermoplastic intermediate layer 3 and the third thermoplastic intermediate layer 10.

[0121] Fig. Figure 10 shows a top view of another embodiment of a layer stack 1, as it may be after step a) of the method. Fig. 22 is the one in the Fig. 10. The embodiment of the layer stack 1 is shown as an exploded view.

[0122] The in the Fig. 10 and Fig. The embodiment of the layer stack 1 shown in Figure 22 differs from the one shown in the Fig. 7 and Fig. Figure 19 shows only that the vent channel 9 is not formed as a recess 13 in the third thermoplastic intermediate layer 10, but rather through a hole 14 in the inner disk 6 and the second thermoplastic intermediate layer 5, wherein the hole 14, when viewed through the layer stack 1, is located in an area where the vent network 8 is situated. The hole 14 has, for example, a diameter of 3 mm.

[0123] It is understood that in this embodiment the layer stack 1 is arranged in a vacuum bag in step b) of the method.

[0124] Furthermore, it is understood that the hole 14 can also be formed in the outer disk 2 and the first thermoplastic intermediate layer 3 instead of in the inner disk 6 and the second thermoplastic intermediate layer 5, although this is not preferred.

[0125] Fig. Figure 11 shows a top view of another embodiment of a layer stack 1, as it may be after step a) of the method. Fig. 23 is the one in the Fig. The embodiment of layer stack 1 shown in Figure 11 is depicted as an exploded view.

[0126] The in the Fig. 11 and Fig. The embodiment of the layer stack 1 shown in Figure 23 differs from the one shown in the Fig. 7 and Fig. Figure 19 shows only that the recess 11 in the third thermoplastic intermediate layer 10 corresponds to the dimensions of the photovoltaic module 4 in terms of its external dimensions.

[0127] Fig. Figure 12 shows a top view of another embodiment of a layer stack 1, as it may be after step a) of the method. Fig. 24 is the one in the Fig. 12. The embodiment of the layer stack 1 is shown as an exploded view.

[0128] The in the Fig. 12 and Fig. The embodiment of the layer stack 1 shown in Figure 24 differs from the one shown in the Fig. 11 and Fig. 23 shown only insofar as the vent channel 9 is not formed as a recess 13 in the third thermoplastic intermediate layer 10, but as a recess 13 in the second thermoplastic intermediate layer 5.

[0129] It is understood that the vent channel 9 can alternatively be formed as a recess 13 in the first thermoplastic intermediate layer 3 instead of as a recess 13 in the second thermoplastic intermediate layer 5.

[0130] Fig. Figure 13 shows a top view of another embodiment of a layer stack 1, as it may be after step a) of the method. Fig. 25 is the one in the Fig. The embodiment of layer stack 1 shown in Figure 13 is depicted as an exploded view.

[0131] The in the Fig. 13 and Fig. The embodiment of the layer stack 1 shown in Figure 25 differs from the one shown in the Fig. 11 and Fig. The difference shown in Figure 23 is only that the vent channel 9 is not formed as a recess 13 in the third thermoplastic intermediate layer 10, but rather that two strips of a fourth thermoplastic intermediate layer 12 are arranged side by side in the layer stack 1 between the third thermoplastic intermediate layer 10 and the second thermoplastic intermediate layer 5, and the vent channel 9 is formed between the strips of the fourth thermoplastic intermediate layer 12. The strips of a fourth thermoplastic intermediate layer 12 have, for example, a width of 3 mm and a thickness of 0.38 mm. It is understood that the length of the strips corresponds to the distance from the vent channel network 8 to the side edge of the layer stack 1. The strips of the fourth thermoplastic intermediate layer 12 are arranged essentially parallel to each other, and the shortest distance between the two strips is, for example, 3 mm.The fourth thermoplastic intermediate layer 12 consists, for example, of PVB.

[0132] It is understood that both strips of the fourth thermoplastic intermediate layer 12 can alternatively be arranged between the third thermoplastic intermediate layer 10 and the first thermoplastic intermediate layer 3 instead of between the third thermoplastic intermediate layer 10 and the second thermoplastic intermediate layer 5, so that the vent channel 9 is arranged between the first thermoplastic intermediate layer 3 and the third thermoplastic intermediate layer 10.

[0133] Fig. Figure 14 shows a top view of another embodiment of a layer stack 1, as it may be after step a) of the method. Fig. 26 is the one in the Fig. The embodiment of layer stack 1 shown in Figure 14 is depicted as an exploded view.

[0134] The in the Fig. 14 and Fig. The embodiment of the layer stack 1 shown in Figure 26 differs from the one shown in the Fig. 11 and Fig. Figure 23 shows only that the vent channel 9 is not formed as a recess 13 in the third thermoplastic intermediate layer 10, but rather through a hole 14 in the inner disk 6 and the second thermoplastic intermediate layer 5, wherein the hole 14, when viewed through the layer stack 1, is located in an area where the vent network 8 is situated. The hole 14 has, for example, a diameter of 3 mm.

[0135] It is understood that in this embodiment the layer stack 1 is arranged in a vacuum bag in step b) of the method.

[0136] Furthermore, it is understood that the hole 14 can also be formed in the outer disk 2 and the first thermoplastic intermediate layer 3 instead of in the inner disk 6 and the second thermoplastic intermediate layer 5, although this is not preferred.

[0137] Fig. Figure 27 shows a top view of another embodiment of a layer stack 1, as it may be after step a) of the method. The Fig. The embodiment of the layer stack 1 shown in plan view in Figure 27 differs from the one shown in the Fig. Figure 4 shows only that the second thermoplastic intermediate layer 5 has not just one recess 13, but two recesses 13. Thus, the one shown in the Fig. 27 layer stacks shown have two vent channels 9, wherein the two vent channels 9 are arranged on opposite sides of the layer stack 1.

[0138] Fig. Figure 28 shows a top view of another embodiment of a layer stack 1, as it may be after step a) of the method. The Fig. The embodiment of the layer stack 1 shown in plan view in Figure 28 differs from the one shown in the Fig. Figure 7 shows only that the third thermoplastic intermediate layer 10 has not just one recess 13, but two recesses 13. Thus, the one shown in the Fig. 28 layer stacks shown have two vent channels 9, wherein the two vent channels 9 are arranged on opposite sides of the layer stack 1.

[0139] It goes without saying that those in the Fig. The embodiments shown in 2, 5, 6, and 8 to 14 can be modified such that the layer stack 1 has more than one vent channel 9, wherein the vent channels 9 can also be formed in different layers of the layer stack 1.

[0140] In the figures, the composite disk, the outer disk, and the inner disk are each shown in a planar configuration. It is understood that the composite disk, the outer disk, and the inner disk can be either planar or curved. Preferably, the composite disk, the outer disk, and the inner disk are each curved.

[0141] For the sake of simplicity, the electrical connections of the photovoltaic module, such as connectors between the solar cells when more than one solar cell is present, or busbars, are not shown in the figures. These connections allow, for example, the solar cells to be interconnected and the photovoltaic module to be connected to the vehicle's electrical system, for instance, to charge the vehicle battery. Reference symbol list: 1 layer stack 2 Outer pane 3 first thermoplastic intermediate layer 4 photovoltaic modules 5 second thermoplastic intermediate layer 6 inner disc 7 solar cell 8 ventilation duct network 9. Ventilation duct 10 third thermoplastic intermediate layer 11 recess 12 fourth thermoplastic intermediate layer 13 Exclusion 14 holes A'-A Intersection line QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] WO 03028114A2

[0002] EP 1036683A2

[0003] WO 2013182398A1

[0004] WO 2013182399A1

[0004] EP 1997614B1

[0008] US 6481482B1

[0008] EP 0605994A1

[0010] JP 2002185027A

[0011]

Claims

[1] Composite sheet with a photovoltaic module (4) manufactured by a process comprising at least the following steps a) Providing a stack of layers (1) comprising at least an outer pane (2), a first thermoplastic intermediate layer (3), a photovoltaic module (4), a second thermoplastic intermediate layer (5) and an inner pane (6), wherein the photovoltaic module (4) comprises at least one solar cell (7) and is arranged between the outer pane (2) and the inner pane (6), the first thermoplastic intermediate layer (3) is arranged between the outer pane (2) and the photovoltaic module (4), the second thermoplastic intermediate layer (5) is arranged between the photovoltaic module (4) and the inner pane (6), at least in certain areas between the photovoltaic module (4) and the first thermoplastic intermediate layer (3) and / or the second thermoplastic intermediate layer (5) a space for air passage is formed in such a way that a ventilation network (8) is formed, and the layer stack (1) has at least one ventilation duct (9) extending from the ventilation network (8) to the surroundings; b) Arranging the stack of layers (1) in a vacuum bag or arranging a vacuum ring around the stack of layers (1); c) Heating the stack of layers (1) to a temperature between 30 °C and 70 °C; d) Venting the heated stack of layers (1) at a temperature between 30 °C and 70 °C; e) Gradual increase of the temperature to a temperature between 100 °C and 130 °C to form a vented pre-composite; f) Removal of the vacuum bag or vacuum ring; g) Lamination of the deaerated pre-composite in an autoclave, wherein the layer stack (1) additionally comprises a third thermoplastic intermediate layer (10) with a recess (11) which is arranged between the first thermoplastic intermediate layer (3) and the second thermoplastic intermediate layer (5) and surrounds the photovoltaic module (4) in a frame-like manner, wherein an air passage gap is formed between the photovoltaic module (4) and the third thermoplastic intermediate layer (10) and the ventilation network (8) encompasses the gap between the third thermoplastic intermediate layer (10) and the photovoltaic module (4). or wherein two strips of a fourth thermoplastic intermediate layer (12) are arranged side by side between the first thermoplastic intermediate layer (3) and the second thermoplastic intermediate layer (5) and a venting channel (9) is formed between the strips of the fourth thermoplastic intermediate layer (12), which extends from the venting channel network to a side edge of the layer stack (1) and / or wherein at least one vent channel (9) is formed by a recess (13) designed as a perforation in the first thermoplastic intermediate layer (3), which extends from the vent channel network (8) to a side edge of the layer stack (1) and / or at least one vent channel (9) is formed as a recess (13) designed as a perforation in the second thermoplastic intermediate layer (5), which extends from the vent channel network (8) to a side edge of the layer stack (1), and / or wherein at least one vent channel (9) is formed through a hole (14) in the inner disc (6) and the second thermoplastic intermediate layer (5) or through a hole (14) in the outer disc (2) and the first thermoplastic intermediate layer (3), which, when viewed through the layer stack (1), is located in an area where the vent channel network (8) is located, and in step b) the layer stack (1) is arranged in a vacuum bag. [2] Composite disc according to claim 1, wherein the photovoltaic module (4) comprises at least two solar cells (7) and an air passage space is formed between each pair of adjacent solar cells (7), which is also included in the ventilation network (8). [3] Composite disc according to claim 1 or 2, wherein at least one vent channel (9) is formed by a recess (13) in the third thermoplastic intermediate layer (10), which extends from the vent channel network (8) to a side edge of the layer stack (1). [4] Composite disc according to one of claims 1 to 3, wherein two strips of a fourth thermoplastic intermediate layer (12) are arranged side by side between the first thermoplastic intermediate layer (3) and the third thermoplastic intermediate layer (10) or between the second thermoplastic intermediate layer (5) and the third thermoplastic intermediate layer (10), and a venting channel (9) is formed between the strips of the fourth thermoplastic intermediate layer (12), which extends from the venting channel network (8) to a side edge of the layer stack (1). [5] Composite disc according to any one of claims 1 to 4, wherein the outer disc (2) and the inner disc (6) are curved and / or wherein the first thermoplastic interlayer (2), the second thermoplastic interlayer (5), the third thermoplastic interlayer (10) and / or the fourth thermoplastic interlayer (12) independently contain or consist of polyvinyl butyral (PVB), ethylene vinyl acetate (EVA) and / or thermoplastic polyolefin (TPO) and / or wherein the outer disc (2) has a lower iron content than the inner disc (6). [6] Composite disc according to one of claims 1 to 5, wherein the layer stack (1) has at least two ventilation channels (9) extending from the ventilation network (8) to the environment. [7] Composite disc according to one of claims 1 to 6, wherein the layer stack (1) has a maximum of eight, preferably a maximum of four, particularly preferably a maximum of two ventilation channels (9) extending from the ventilation network (8) to the environment. [8] Composite glass according to one of claims 1 to 7, wherein the inner glass (6) and / or the second thermoplastic intermediate layer (5) is tinted or colored at least in certain areas and / or wherein one of the surfaces of the outer glass (2) is provided with an opaque cover print in a circumferential edge area and / or one of the surfaces of the inner glass (6) is provided with an opaque cover print in a circumferential edge area or over the entire surface.

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