Method of incorporating a solar panel into a vehicle body part

Abstract

A method for connecting a solar panel to a frame of a vehicle body portion, the method comprising the steps of: providing a recess in the frame of the vehicle body portion; providing at least one inlet opening in the recess, the at least one inlet opening providing a first passage between the recess and the interior of the vehicle body portion; positioning the solar panel over the recess, thereby defining a predetermined volume by the solar panel and the recess; after positioning the solar panel over the recess, supplying a filling material into the recess through the at least one inlet opening; and filling the volume with the filling material to connect the solar panel to the frame with the filling material.

Description

【Technical Field】 【0001】 The present invention relates to a method of incorporating a solar panel into a vehicle body part such as a door, a side panel, a trunk, or a roof of a vehicle. 【Background Art】 【0002】 Photovoltaic (PV) technology is mainly used in grid-connected applications, and currently, PV applications in remote areas are rapidly increasing, such as providing solar panels on the roofs of electric vehicles. In this way, the vehicle becomes less energy-dependent and more environmentally friendly. Generally, a solar panel includes a plurality of solar cells connected in series. 【0003】 To provide a solar panel for a vehicle, the solar panel is typically attached to the outer surface of the vehicle. 【0004】 A disadvantage of providing a solar panel for a vehicle is that the total weight of the vehicle increases. The overall weight increase requires more energy to accelerate the vehicle, thus reducing the energy efficiency of the vehicle. 【Prior Art Documents】 【Patent Documents】 【0005】 【Patent Document 1】 International Publication No. 2022 / 122507 【Patent Document 2】 International Publication No. 2010 / 017847 【Summary of the Invention】 【Problems to be Solved by the Invention】 【0006】 Therefore, an object of the present invention is to provide a method, or at least an alternative method, for providing a vehicle body part with a solar panel that can achieve a lighter structure while maintaining the structural strength. 【Means for Solving the Problem】 【0007】 The object of the present invention is achieved by a method of connecting a solar panel to a frame of a vehicle body part, the method comprising the following steps: - providing a recess in the frame of the vehicle body part; - providing at least one inlet opening in the recess, the at least one inlet opening providing a first passage between the recess and the interior of the vehicle body part; - positioning the solar panel above the recess, thereby defining a predetermined volume by the solar panel and the recess; - after positioning the solar panel above the recess, supplying a filling material into the recess through the at least one inlet opening; - filling the volume with the filling material to connect the solar panel to the frame with the filling material. 【0008】 For example, the vehicle is an automobile, a train, a bus, etc. The vehicle comprises a vehicle body part. 【0009】 For example, the vehicle body part is a vehicle door, a vehicle roof, a vehicle trunk, or a part thereof. The vehicle body part has a frame. The frame is made of, for example, metal, carbon fiber, glass fiber, or a mixture thereof. Fiber-based components are particularly suitable for use as components of large-area structures such as the roof of a vehicle. For example, the frame provides the required level of strength for the vehicle body part. 【0010】 The solar panel includes solar cells grouped into modules. The solar panel is connected to the frame of the vehicle body part. 【0011】 Therefore, in the method of the present invention, a recess is provided in the frame of the vehicle body portion. The recess is provided on the exterior surface of the vehicle body portion. The recess forms an opening on the exterior surface of the vehicle body portion. The recess is designed such that at least a part of the solar panel fits into the recess. 【0012】 The recess has at least one inlet opening. The at least one inlet opening provides a first passage between the recess and the interior of the vehicle body portion. The at least one inlet opening is provided, for example, at the center of the recess. Preferably, the at least one inlet opening is circular. The diameter of the at least one inlet opening is between 8 mm and 40 mm, preferably between 10 mm and 30 mm, more preferably between 10 mm and 20 mm. 【0013】 When the solar panel is positioned on the recess, a predetermined volume is defined between the solar panel and the recess. When positioning the solar panel on the recess, the solar panel is preferably positioned relative to the frame such that the solar panel is flush with the exterior surface of the vehicle body portion. For example, the solar panel is integrated with the frame of the vehicle body portion. For example, the frame has an edge around the opening defined by the recess. The periphery of the solar panel is placed on the edge of the frame. If necessary, before positioning the solar panel on the recess, an adhesive or a kit is applied to the edge of the frame. The adhesive or the kit can be applied as a line or a dot. The adhesive or the kit is preferably a UV-curable adhesive or a kit. Alternatively or additionally, the adhesive or the kit is applied to the edge of the solar panel. 【0014】 After the step of positioning the solar panel on the recess, the filling material is supplied to the recess through at least one inlet opening. For example, at least one inlet opening is configured to be connected to a hose that transfers the filling material to the recess through at least one inlet opening. The volume between the solar panel and the recess is filled with the filling material through at least one inlet opening, connecting the solar panel to a frame having the filling material. For example, the volume is completely filled or partially filled with the filling material. When the volume is partially filled with the filling material, the filling material is applied so as to contact both the solar panel and the frame. For example, the recess is provided with walls that define separate partitions of the volume. The filling material is provided, for example, on one or more partitions, but not on one or more other partitions. Preferably, the filling material is a lightweight material. 【0015】 According to one embodiment, the filling material is a foamed filling material. Due to the foamed structure of the foamed filling material, it contributes to the impact resistance of the vehicle body part. Preferably, the filling material is a polyurethane (PUR) filling material. The PUR filling material has the advantage of being a lightweight and hard material. When the PUR filling material is applied, the impact resistance of the solar panel is also improved. 【0016】 By providing a plurality of inlet openings, for example three inlet openings, in the recess, and thereby using a filling device for each inlet opening, the volume between the solar panel and the frame can be filled more quickly and more uniformly. Thereby, the production time of the vehicle body part is shortened. 【0017】 According to one embodiment, the method according to the invention further comprises the following steps: - providing at least one outlet opening in the recess, the at least one outlet opening providing a second passage between the recess and the interior of the vehicle body part; - When the filling material exits the recess into the interior of the vehicle body part through at least one outlet opening, stopping the supply of the filling material through the at least one inlet opening. 【0018】 The recess has at least one outlet opening. The at least one outlet opening provides a second passage between the recess and the interior of the vehicle body part. The at least one outlet opening is arranged, for example, at the edge of the recess. Preferably, the at least one outlet opening is circular. The diameter of the at least one outlet opening is between 8 mm and 40 mm, preferably between 10 mm and 30 mm, more preferably between 10 mm and 20 mm. 【0019】 During filling of the volume part with the filling material through at least the inlet opening, there is a moment when the volume part is completely filled with the filling material. The moment when the volume part is completely filled is visually detectable when the filling material is exiting the recess into the interior of the vehicle body part through at least one outlet opening. Thereafter, the supply of the filling material through at least one inlet opening is stopped. Thereby, only the necessary amount of filling material is used to fill the volume part in order to securely connect the solar panel to the frame. Thereby, the risk of waste of the filling material and underfill of the volume part is avoided. 【0020】 According to one embodiment, the method according to the invention further comprises the step of forming a recess in the frame of the vehicle body part. For example, the recess in the frame is formed by hydroforming. In the case of a metal vehicle door, the recess in the frame is formed by stamping or hydroforming. 【0021】 According to one embodiment, the method according to the invention further comprises the following steps: - After the step of positioning the solar panel above the recess, a step of sealing at least a part of the periphery of the solar panel to the recess. By sealing at least a part of the periphery of the solar panel to the recess, the position of the solar panel with respect to the vehicle body part can be fixed. Thereby, the execution of the filling process of the volume part becomes easy. For example, at least a part of the periphery of the solar panel is adhered to the recess. Alternatively, putty can also be used as a sealing material. Preferably, the sealing is based on polyurethane, for example a polyurethane line joint. Polyurethane has the advantage of being a lightweight and inexpensive material. Preferably, the sealing is a watertight seal. 【0022】 According to one embodiment, the method according to the invention further comprises the following steps: - A step of providing at least one structural frame element inside the vehicle body part outside the volume part to the frame. 【0023】 The at least one structural frame element is, for example, a bar, for example a metal bar. The at least one structural frame element is configured to enhance the impact resistance of the vehicle body part. For example, for example due to a collision of the vehicle, a collision that imparts an impact to the vehicle body part may substantially deform the vehicle body part. When the vehicle body part is a vehicle door, a passenger sitting next to the vehicle door is safer against a (severe) impact on the vehicle body part. The structural frame element absorbs at least a part of the impact force, leading to a safer structure of the vehicle body part. 【0024】 According to one embodiment, the method according to the invention further comprises the following steps: - Before the step of providing the filling material to the recess through the at least one inlet opening, a step of providing a cut-out opening inside the vehicle body part, the cut-out opening providing a third passage between the recess and the inside of the vehicle body part; - A step of attaching a temporary cover to the cut-out opening; - After the step of filling the volume part with the filling material, a step of curing the filling material; - After curing the filling material, a step of removing the temporary cover. 【0025】 The notch opening inside the vehicle body part provides a passage between the recess and the inside of the vehicle body part. The notch opening is provided adjacent to, for example, at least one inlet opening and / or at least one outlet opening. Alternatively or additionally, the notch opening is formed within the recess. For example, a notch opening is formed in the recess by laser cutting. 【0026】 Thereafter, a temporary cover is applied over the notch opening. The temporary cover covers at least the notch opening. The temporary cover is clamped to the recess, for example, such that the temporary cover is pressed against the recess while covering the notch opening. 【0027】 When the temporary cover is applied over the notch opening, the volume part between the solar panel and the recess is filled with the filling material. After filling the volume part, the filling material is cured. After curing the filling material, the temporary cover is removed. By providing the notch opening and applying the temporary cover, a vehicle body part incorporating a lighter solar panel can be realized. 【0028】 In one embodiment, the temporary cover has a coating. Preferably, the coating is a polytetrafluoroethylene coating. For example, the coating is a non-sticky permanent layer. For example, the coating is a non-sticky spray. The coating enables easier removal of the temporary cover from the cured filling material. 【0029】 According to one embodiment, the method according to the present invention further includes the following steps: - A step of providing at least one structural frame element extending through the recess before positioning the solar panel on the recess, wherein after the step of filling the volume portion with the filling material, the filling material surrounds the at least one structural frame element. 【0030】 At least one structural frame element is configured to enhance the impact resistance of the vehicle body part. By providing at least one structural frame element, such as a metal bar, extending through the recess, a more compact connection of the solar panel to the frame of the vehicle body part can be achieved. Since the filler surrounds the at least one structural frame element, for example, for aesthetic reasons, no additional layer is required to hide the at least one structural frame element. 【0031】 According to one embodiment, the solar panel is a single curved panel. Alternatively, the solar panel is a double-curved panel curved in two different directions. When using a double-curved panel, the solar panel can more easily follow the contour of the vehicle body part when connected to the frame of the vehicle body part, thus more easily reducing the aerodynamic drag coefficient of the vehicle. 【0032】 In one embodiment, a vehicle body part manufactured according to any of the above embodiments is provided. By using the vehicle body part, a lighter structure can be realized while maintaining the structural strength when connecting the solar panel to the frame of the vehicle body part. 【0033】 In one embodiment, a vehicle door including the vehicle body part according to the present invention is provided. 【Brief Description of the Drawings】 【0034】 【Figure 1a】 A first embodiment of a method according to the present invention for connecting a solar panel to a frame of a vehicle body part is schematically shown. 【Figure 1b】 A first embodiment of a method according to the present invention for connecting a solar panel to a frame of a vehicle body part is schematically shown. 【Figure 1c】 Figure 1 schematically shows a first embodiment of a method according to the present invention for connecting a solar panel to a frame of a vehicle body part. 【Figure 2a】 Figure 2 schematically shows a second embodiment of a method according to the present invention for connecting a solar panel to a frame of a vehicle body part. 【Figure 2b】 Figure 2 schematically shows a second embodiment of a method according to the present invention for connecting a solar panel to a frame of a vehicle body part. 【Figure 2c】 Figure 2 schematically shows a second embodiment of a method according to the present invention for connecting a solar panel to a frame of a vehicle body part. 【Figure 2d】 Figure 2 schematically shows a second embodiment of a method according to the present invention for connecting a solar panel to a frame of a vehicle body part. BEST MODE FOR CARRYING OUT THE INVENTION 【0035】 Hereinafter, the present invention will be described with reference to the drawings. These drawings serve as examples for explaining the present invention and are not to be construed as limiting the scope of the claims. In different drawings, similar features are denoted by similar reference numerals. 【0036】 Figs. 1a to 1c schematically show embodiments of a method according to the present invention for connecting a solar panel to a frame of a vehicle body part. Cross-sectional views of the vehicle body part 1 are shown in Figs. 1a to 1c. 【0037】 In Figs. 1a to 1c, the vehicle body part 1 is, for example, a part of a vehicle door. In this case, Figs. 1a to 1c show a top view of the vehicle body part 1. Alternatively, when the vehicle body part is, for example, a part of a vehicle roof, Figs. 1a to 1c are front views of the vehicle body part 1. 【0038】 The vehicle body part 1 has a frame 2. The frame 2 is made of, for example, metal, carbon fiber, or glass fiber, or a mixture thereof. Fiber-based components are particularly suitable for use as components of large-area structures such as the roof of the vehicle. The frame 2 is, for example, corresponding to the strength required for the vehicle body part 1. 【0039】 The frame 2 is defined by an exterior surface 4 and an interior surface 7. The exterior surface 4 is provided on the outside 4a of the vehicle body part 1. The interior surface 7 is arranged on the inside 7a of the vehicle body part 1. For example, an insulating material is provided between the exterior surface 4 and the interior surface 7. 【0040】 In FIG. 1a, a recess 3 is provided in the frame 2 of the vehicle body part 1. For example, the recess 3 in the frame 2 is formed by hydroforming. 【0041】 The recess 3 is provided on the outer surface 4 of the vehicle body part 1. The exterior surface 4 has an outer side 4a, that is, the outer side 4a of the vehicle body part 1. The recess 3 forms an opening 3a in the exterior surface 4 of the vehicle body part 1. The recess 3 is designed to fit at least a part of the solar panel 5. 【0042】 In FIG. 1a, the solar panel 5 is a single curved panel having a curvature in the x direction (refer to the assigned coordinate system). Alternatively, the solar panel 5 is a double-curved panel, and the solar panel is curved in two different directions, for example, the x direction and its perpendicular direction (i.e., the direction coming out of the paper). When using a double-curved panel, when the solar panel 5 is connected to the frame 2 of the vehicle body part 1, it follows the contour of the vehicle body part 1, and thus, it is more easily realized to reduce the aerodynamic drag coefficient of the vehicle. 【0043】 The recess 3 is provided with an inlet opening 6. The inlet opening 6 forms a first passage 6a between the recess 3 and the inner side 7a of the vehicle body portion 1. The inlet opening 6 is provided at the center of the recess 3. Preferably, the inlet opening 6 is circular. The diameter of the inlet opening 6 is 8 mm to 40 mm, preferably 10 mm to 30 mm, more preferably 10 mm to 20 mm. 【0044】 Further, the recess 3 is provided with two outlet openings 8. Each outlet opening 8 forms a second passage 8a between the recess 3 and the inner side 7a of the vehicle body portion 1. The two outlet openings 8 are located near the edge of the recess 3. Preferably, each outlet opening 8 is circular. The diameter of each outlet opening 8 is 8 mm to 40 mm, preferably 10 mm to 30 mm, more preferably 10 mm to 20 mm. 【0045】 Also, two structural frame elements 9 are provided on the frame 2 of the inner side 7a of the vehicle body portion 1. The structural frame element 9 is a metal bar. The structural frame element 9 is for enhancing the impact resistance of the vehicle body portion 1. For example, when a collision impact is applied to the vehicle body portion 1 due to a collision of the vehicle, the vehicle body portion 1 may be substantially deformed. 【0046】 In the embodiment shown in FIGS. 1a to 1c where the vehicle body portion 1 is part of a vehicle door, a passenger sitting next to the vehicle door is more reliably protected against (severe) impacts on the vehicle body portion 1. Since the structural frame element 9 absorbs at least a part of the collision force, the vehicle body portion 1 can be configured to be safer. 【0047】 In Fig. 1b, the solar panel 5 is positioned above the recess 3. When the solar panel 5 is positioned above the recess 3, a volume portion 10 is formed between the solar panel 5 and the recess 3. The solar panel 5 is positioned with respect to the frame 2 so as to be flush with the exterior surface 4 of the vehicle body portion 1. In Fig. 1b, the solar panel 5 is integrated within the frame 2 of the vehicle body portion 1. The frame 2 is provided with an edge portion 11 around the opening formed by the recess 3. The periphery of the solar panel 5 is placed on the edge portion 11 of the frame 2. 【0048】 Preferably, at least a part of the periphery of the solar panel 5 is sealed to the recess 3 after the step of positioning the solar panel 5 above the recess 3. By sealing at least a part of the periphery of the solar panel 5 to the recess 3, the position of the solar panel 5 with respect to the vehicle body portion 1 can be fixed. For example, at least a part of the periphery of the solar panel 5 is adhered to the recess 3. Alternatively, putty can also be used as a sealing material. Preferably, the sealing is based on polyurethane, for example a polyurethane line joint. Polyurethane has the advantage of being a lightweight and inexpensive material. Preferably, the sealing is a watertight seal. 【0049】 After the step of positioning the solar panel 5 over the recess 3, the filling material 12 is provided in the recess 3 via the inlet opening 6. This is visualized in FIG. 1c. The first passage 6a is provided with, for example, a filling device (not shown). The filling device transfers the filling material 12 through the first passage 6a and via the inlet opening 6 into the recess 3. Alternatively, the inlet opening 6 is configured to be connected to a hose that transfers the filling material 12 into the recess 3 via the inlet opening 6. The volume 10 between the solar panel 5 and the recess 3 is filled with the filling material 12, and the filling material 12 connects the solar panel 5 to the frame 2. The volume 10 is completely filled with the filling material 12 (visualized by the dashed-line area). Alternatively, the volume 10 is partially filled with the filling material 12. When the volume 10 is partially filled with the filling material 12, the filling material 12 is applied so as to contact both the solar panel 5 and the frame 2. Preferably, the filling material 12 is a lightweight material. 【0050】 Note that in one embodiment, the filling material 12 is transferred to the volume 10 disposed over the solar panel 5. In such an embodiment, the filling material 12 flows downward when filling the volume 10, rather than laterally as shown in the configuration of FIG. 1c. There is no limitation on the orientation of the solar panel 5 with respect to the volume 10 regarding the step of filling the volume 10 with the filling material 12. 【0051】 According to one embodiment, the filling material 12 is a foamed filling material. Due to the foamed structure of the foamed filling material, the foamed filling material contributes to the impact resistance of the vehicle body part 1. Preferably, the filling material 12 is a polyurethane (PUR) filling material. The PUR filling material has the advantage of being a lightweight and hard material. 【0052】 During filling the volume part 10 with the filling material 12 through the inlet opening 6, there is a moment when the volume part 10 is completely filled with the filling material 12. The moment when the volume part 10 is completely filled is visually detectable when the filling material 12 exits from the recess 3 through at least one outlet opening 8 to the inside 7 of the vehicle body part 1 via the second passage 8a. Then, the supply of the filling material 12 through one of the inlet openings 6 is stopped. Thereby, only the necessary amount of the filling material 12 is used to fill the volume part 10 in order to securely connect the solar panel 5 to the frame 2. Thereby, the risk of waste of the filling material 12 or underfilling of the volume part 10 is avoided. 【0053】 Figures 2a to 2d schematically show a second embodiment of the method according to the invention for connecting a solar panel to a frame of a vehicle body part. Cross-sectional views of the vehicle body part 21 are shown in Figures 2a to 2d. 【0054】 In Figures 2a to 2d, the vehicle body part 21 is, for example, part of a vehicle trunk. Here, Figures 2a to 2d are front views of the vehicle body part 1. 【0055】 The frame 2 of the vehicle body part 21 is defined by the exterior surface 4. The exterior surface 4 has an outer side 4a, i.e., the outer side 4a of the vehicle body part 21, and an inner side 7a, i.e., the inner side 7a of the vehicle body part 21. The two sides 4a, 7a are arranged opposite to each other. 【0056】 In Figures 2a to 2d, two structural frame elements 9 are provided in the recess 3. The structural frame elements 9 extend through the recess 3. 【0057】 In Figure 2a, the solar panel 5 is positioned above the recess 3. Also, a notch opening 22 is provided in the inner side 7a of the vehicle body part 21. The notch opening 22 forms a third passage 22a between the recess 3 and the inner side 7a of the vehicle body part 21. The notch opening 22 is provided adjacent to the inlet opening 6 and the outlet opening 8. The notch opening 22 is formed in the recess 3, for example, by laser cutting. 【0058】 Subsequently, the temporary cover 23 is applied over the notch opening 22 (see FIG. 2b). The temporary cover 23 covers the notch opening 22. The temporary cover 23 is clamped to the recess 3, for example, so as to be pressed against the recess 3 in a state covering the notch opening 22. 【0059】 In FIG. 2c, the volume portion 10 between the solar panel 5 and the recess 3 is filled with the filler 12. The filler 12 surrounds the structural frame element 9. 【0060】 After filling the volume portion 10, the filler 12 is cured. After curing of the filler 12, the temporary cover 23 is removed (see FIG. 2d). 【0061】 By providing the notch opening 22 and applying the temporary cover 23, a vehicle body portion incorporating a lighter solar panel can be realized.

Claims

[Claim 1] A method for connecting solar panels to the frame of the vehicle body, - The step of providing a recess in the frame of the vehicle body portion, - A step of providing at least one entrance opening within the recess, wherein the at least one entrance opening provides a first passage between the recess and the interior of the vehicle body portion, - The steps of positioning the solar panel on the recess and thereby defining a predetermined volume area with respect to the solar panel and the recess, - After the step of positioning the solar panel on the recess, the step of supplying a filler material to the recess through at least one inlet opening, - A step of filling the volume portion with the filler material in order to connect the solar panel to the frame with the filler material, Methods that include... [Claim 2] - A step providing at least one exit opening within the recess, the at least one exit opening providing a second passage between the recess and the interior of the vehicle body portion, - The step of stopping the supply of the filler through the at least one inlet opening when the filler exits from the recess into the interior of the vehicle body portion through the at least one outlet opening, The method according to claim 1, further comprising: [Claim 3] - After the step of positioning the solar panel on the recess, the step of sealing at least a portion of the area around the solar panel into the recess, The method according to claim 1, further comprising: [Claim 4] The method according to claim 3, wherein the step of sealing at least a portion of the periphery of the solar panel into the recess includes the step of bonding at least a portion of the periphery of the solar panel to the recess. [Claim 5] - The step of forming the recess in the frame of the vehicle body portion, The method according to claim 1, further comprising: [Claim 6] - Providing at least one structural frame element to the frame inside the vehicle body portion outside the volume portion, The method according to claim 1, further comprising: [Claim 7] - Before the step of providing the filler material to the recess through the at least one inlet opening, the step of providing a notch opening inside the vehicle body portion, the notch opening providing a third passage between the recess and the inside of the vehicle body portion, - The step of attaching a temporary cover to the aforementioned notched opening, - After the step of filling the volume portion with the filler, the step of hardening the filler, - After the filler has hardened, the temporary cover is removed. The method according to claim 1, further comprising: [Claim 8] The method according to claim 7, wherein the temporary cover has a coating. [Claim 9] - A step of providing at least one structural frame element extending through the recess before positioning the solar panel on the recess, wherein, after filling the volume portion with the filler, the filler surrounds the at least one structural frame element. The method according to claim 1, further comprising: [Claim 10] The method according to claim 1, wherein the filler is a foamed filler. [Claim 11] The method according to claim 1, wherein the solar panel is a single curved panel or a double curved panel. [Claim 12] A vehicle body portion manufactured according to the method described in claim 1. [Claim 13] A vehicle door comprising the body portion described in claim 12.

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