Method for producing a composite pane having a photovoltaic module

Abstract

The present invention relates to a method for producing a composite pane having a photovoltaic module (4), at least comprising the following steps: a) providing a layer stack (1) at least comprising 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 an intermediate space for the passage of air is formed at least in regions between the photovoltaic module (4) and the first thermoplastic intermediate layer (3) and / or the second thermoplastic intermediate layer (5) in such a way that a ventilation path network (8) is formed, and the layer stack (1) comprises at least one ventilation channel (9) extending from the ventilation path network (8) to the surrounding region; b) arranging the layer stack (1) in a vacuum bag or arranging a vacuum ring around the layer stack (1); c) heating the layer stack (1) to a temperature between 30°C and 70°C; d) ventilating the heated layer stack (1) at a temperature between 30°C and 70°C; e) gradually increasing the temperature to a temperature between 100°C and 130°C to form a ventilated pre-composite; f) removing the vacuum bag or vacuum ring; g) laminating the ventilated pre-composite.

Description

[0001] METHOD FOR PRODUCING A COMPOSITE PANE WITH A PHOTOVOLTAIC MODULE

[0002] The invention relates to a method for producing a composite pane with a photovoltaic module, a composite pane produced by the method and its use.

[0003] It is well known that glazing can be equipped with photovoltaic components to generate electrical energy. For example, W003028114A2 discloses insulating glazing with a photovoltaic module. Insulating glazing is used primarily as building glazing.

[0004] Glazing with photovoltaic components can also be of interest in the automotive sector, particularly as vehicle roof panels. The photovoltaic components can be used, for example, to charge the on-board battery or power electrical devices. This is becoming increasingly important, especially in connection with electric vehicles. EP1036683A2 discloses a vehicle roof panel designed as a single pane of glass and equipped with a solar cell assembly on the interior side.

[0005] Vehicle roof windows are often designed as composite panes, comprising an outer pane and an inner pane bonded together via a thermoplastic intermediate layer. In such composite panes, the photovoltaic components can be embedded in the intermediate layer, as is known, for example, from WO2013182398A1 and WO2013182399A1.

[0006] To manufacture vehicle roof windows with photovoltaic modules, the photovoltaic 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.

[0007] Solar cells are generally very brittle and can easily break during the lamination process. Lamination can also cause microcracks in the solar cell, which weaken the cell. 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.

[0008] Microcracks are not directly visible to the naked eye, but can be visualized 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.

[0009] Laminated panes with photovoltaic modules are typically laminated using special tools called laminators. The stack to be laminated is heated in a vacuum chamber so that no external forces act on the stack. Once the stack has reached a temperature of 110 °C and the interlayer is soft, mechanical forces are applied via a flexible membrane. The production of laminated panes with photovoltaic modules using laminators is described in EP1997614B1 and US6481482B1.

[0010] From a technical perspective, such laminators are suitable for flat laminated glass panels, as no special tools are required. However, producing curved laminated glass panels with photovoltaic modules would require a special mold for each model to withstand the pressure of the membrane and prevent breakage of the glass panels. This would involve high tooling costs for the various model-specific molds. Furthermore, a large number of tools would be required to enable short cycle times.

[0011] EP0605994A1 discloses a method for encapsulating photovoltaic cells in laminated glazing. The method comprises the steps of providing a polymeric interlayer, tackifying a portion of a major surface of the polymeric interlayer by applying a solvent to the portion, adhering a photovoltaic cell to the tackified portion of the surface of the polymeric interlayer, disposing the polymeric interlayer with the photovoltaic cell adhered thereto between two glass panes, and laminating the glass panes and the polymeric interlayer with the photovoltaic cell adhered thereto, thereby encapsulating the photovoltaic cell in the laminated glazing. 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 portions are formed on the film surface by embossing. Furthermore, connecting paths are provided that connect adjacent recessed portions. The recessed portions and the connecting paths are arranged in a uniform pattern with high periodicity on the film.

[0012] The present invention is based on the object of providing an improved method for producing a composite pane with a photovoltaic module, which is particularly suitable for the production of curved composite panes and in which microcracks and cell breakages in the photovoltaic module are prevented.

[0013] The object is achieved according to the invention by a method according to independent claim 1. Advantageous embodiments emerge from the subclaims.

[0014] Using the electroluminescence method, the inventors discovered that microcracks develop during the venting phase when the glass stack to be vented is subjected to strong mechanical forces.

[0015] Standard lamination technologies for automotive glass are therefore less suitable for laminated panes with photovoltaic modules, especially curved laminated panes with photovoltaic modules, because the thermoplastic interlayers are too hard and exert mechanical forces on the solar cells of the photovoltaic module during the deaeration phase, leading to microcracks and cell breakage. Regardless of the type of interlayer used, a hard thermoplastic interlayer always exerts localized mechanical forces on the solar cells of the photovoltaic module during deaeration, whereas a softer thermoplastic interlayer allows the forces to be distributed across the entire cell surface.If the thermoplastic interlayers used in standard lamination technology are heated to make them softer, the problem arises that ventilation is no longer possible because the thermoplastic interlayers lying on top of each other stick together.

[0016] According to the invention, this problem can be solved by providing at least one

[0017] The venting channel in the layer stack to be vented is released, which closes automatically at higher temperatures after venting. This technology enables reliable venting at higher temperatures and prevents microcracks and cell breakage.

[0018] The method according to the invention for producing a composite pane with a photovoltaic module comprises at least the following steps: a) Providing a layer stack at least comprising an outer pane, a first thermoplastic intermediate layer, a photovoltaic module, a second thermoplastic intermediate layer and an inner pane, b) Arranging the layer stack in a vacuum bag or arranging a vacuum ring around the layer stack, c) Heating the layer stack to a temperature between 30°C and 70°C, d) De-airing the heated layer stack at a temperature between 30°C and 70°C, e) Gradually increasing the temperature to a temperature between 100°C and 130°C to form a de-aired pre-composite, f) Removing the vacuum bag or the vacuum ring, g) Laminating the de-aired pre-composite in an autoclave.

[0019] Step a) is the first step of the method according to the invention. After step a), steps b) and c) are carried out in any order or simultaneously. Step d) follows. Step d) is followed by step e), step e) is followed by step f), and step f) is followed by step g).

[0020] In the layer stack provided in step a), 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 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 in some regions, between the photovoltaic module and the first thermoplastic intermediate layer and / or the second thermoplastic intermediate layer in such a way that a ventilation path network is formed. According to the invention, the layer stack has at least one ventilation channel running from the ventilation path network to the environment.In the sense of the invention, a venting channel is a structure permeable to gases through which any existing air inclusions can escape along the venting channel during the venting of the layer stack in step d).

[0021] In this context, the environment refers to the surroundings of the layer stack, i.e. the areas immediately adjacent to the layer stack.

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

[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 intermediate layers of the layer stack are so soft that significantly reduced localized mechanical forces act on the solar cells of the photovoltaic module, and the forces are distributed more widely 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 heated layer stack is vented, also 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 may also be different, provided that the respective temperatures are between 30°C and 70°C.

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

[0025] The venting of the heated layer stack in step d) takes place at a negative pressure of preferably less than or equal to 0.3 bar, more 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 specifications refer to the absolute pressure, i.e. the pressure compared to the absolute vacuum with p = 0 bar. The venting preferably takes place for a period of time greater than or equal to 8 minutes, for example for a period of time of 30 minutes. As described above, in step e) the temperature is gradually increased to a temperature 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 ventilation network and the at least one ventilation channel, filling and closing them.

[0026] It is understood that in step f) the vacuum bag or the vacuum ring is ventilated before or during removal.

[0027] The lamination of the de-aerated pre-composite to form the composite pane with a 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 lamination of the de-aerated pre-composite in an autoclave are known to those skilled in the art. Lamination in the autoclave can be carried out, for example, at an elevated pressure of approximately 10 bar to 15 bar and temperatures of 130°C to 145°C for approximately 2 hours.

[0028] As described above, the photovoltaic module comprises at least one solar cell. It is understood that the photovoltaic module also includes the necessary electrical connections, such as connectors between the solar cells if there is more than one solar cell, or bus bars.

[0029] An intermediate space for air passage belonging to the ventilation path network can be formed in particular along one or more edges of a solar cell of the photovoltaic module and / or along connectors or bus bars of the photovoltaic module.

[0030] In a particularly preferred embodiment of the method according to the invention, the photovoltaic module has at least two solar cells and between each two solar cells there is formed an intermediate space for the passage of air, which space is also included in the ventilation path network.

[0031] The invention thus also relates to a method for producing a composite pane with a photovoltaic module, at least comprising the following steps: a) providing a layer stack at least comprising 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 some regions between the photovoltaic module and the first thermoplastic intermediate layer and / or the second thermoplastic intermediate layer and between each two adjacent solar cells, an intermediate space for air to pass through is formed in such a way that a ventilation path network is formed, and the layer stack has at least one ventilation channel running from the ventilation path network to the environment;b) arranging the layer stack in a vacuum bag or arranging a vacuum ring around the layer stack, c) heating the layer stack to a temperature between 30 °C and 70 °C, d) venting the heated layer stack at a temperature between 30 °C and 70 °C, e) gradually increasing the temperature to a temperature between 100 °C and 130 °C to form a vented pre-laminate, f) removing the vacuum bag or the vacuum ring, g) lamination of the vented pre-laminate.;

[0032] The gap for air passage between two adjacent solar cells has a width of between 1 mm and 100 mm, preferably between 1 mm and 10 mm, and particularly preferably between 2 mm and 5 mm. In this context, the width of the gap is understood to be the shortest distance between two adjacent solar cells. If the photovoltaic module has more than two solar cells, the gaps for air passage between each two solar cells do not have to be the same width, but can be independently different in size, depending on how the solar cells are arranged in the photovoltaic module. Individual areas of the ventilation path network between the solar cells can therefore have different widths.

[0033] In a preferred embodiment of the method according to the invention, the layer stack additionally comprises a third thermoplastic intermediate layer, which is arranged between the first thermoplastic intermediate layer and the second thermoplastic intermediate layer and has a recess in which the photovoltaic module is accommodated. 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 essentially correspond to the outer dimensions of the photovoltaic module, i.e., the recess and the photovoltaic module have essentially the same geometry.Particularly preferably, the recess is larger in size (length and width) 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 network also 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, in particular the distance is between 1 mm and 6 mm.

[0034] The at least one venting channel can be formed in various ways. The venting channel can be introduced subtractively or applied additively. A subtractively introduced venting channel can be formed by a recess in one of the thermoplastic intermediate layers, extending from the venting path network to a side edge of the layer stack. A subtractively introduced venting channel can also be 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, which, when viewed through the layer stack, is located in a region in which the venting path network is located.An additively applied venting channel can be formed by two adjacently arranged strips of a fourth thermoplastic intermediate layer, wherein the venting channel is formed between the two strips and extends from the venting path network to a side edge of the layer stack.

[0035] It is understood that if the layer stack has two or more venting channels, these can be designed in the same way or in different ways.

[0036] In one embodiment of the method according to the invention, the layer stack additionally comprises 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 at least one venting channel is formed by a recess in the third thermoplastic intermediate layer, which extends from the venting path 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 an intermediate space for air passage is formed between the photovoltaic module and the third thermoplastic intermediate layer, and the venting path network also encompasses the intermediate space between the third thermoplastic intermediate layer and the photovoltaic module.

[0037] The recess in the third thermoplastic intermediate layer is preferably between 1 mm and 5 mm wide, particularly preferably between 2 mm and 3 mm. It is understood that the length of the recess corresponds to the distance from the venting path network to a side edge of the layer stack.

[0038] The recess in the third thermoplastic intermediate layer is preferably formed as an opening, i.e., the recess extends across 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, if the recess in the third thermoplastic intermediate layer is formed as an opening, no material of the third thermoplastic intermediate layer is arranged in the layer stack in the region of the recess.

[0039] In a further embodiment of the method according to the invention, the layer stack 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 next to one another and a ventilation channel is formed between the strips of the fourth thermoplastic intermediate layer and extends from the ventilation path 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 path network also includes the gap between the third thermoplastic intermediate layer and the photovoltaic module.

[0040] In a further embodiment of the method according to the invention, the layer stack 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 next to one another and a ventilation channel is formed between the strips of the fourth thermoplastic intermediate layer and extends from the ventilation path 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 path network also includes the gap between the third thermoplastic intermediate layer and the photovoltaic module.

[0041] In a further embodiment of the process according to the invention, 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 and extends from the venting path network to a side edge of the layer stack. In this embodiment, the layer stack does not have a third thermoplastic intermediate layer.

[0042] The strips of a fourth thermoplastic intermediate layer 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 venting path network to a side edge of the layer stack. The strips of the fourth thermoplastic intermediate layer are preferably arranged substantially parallel to one another, and the shortest distance between the two strips is preferably between 1 mm and 5 mm, particularly preferably between 2 mm and 3 mm.It is understood that in further embodiments of the method, 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 then formed between each two adjacent strips of the fourth thermoplastic intermediate layer, which venting channel extends from the venting path network to a side edge of the layer stack.

[0043] In a further embodiment of the method according to the invention, at least one venting channel is formed by a recess in the first thermoplastic intermediate layer, which extends from the venting path network to a side edge of the layer stack. Optionally, the layer stack in this embodiment can additionally comprise 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.

[0044] The recess in the first thermoplastic intermediate layer is preferably between 1 mm and 5 mm wide, particularly preferably between 2 mm and 3 mm. It is understood that the length of the recess corresponds to the distance from the venting path network to a side edge of the layer stack.

[0045] The recess in the first thermoplastic intermediate layer is preferably formed as an opening, i.e., the recess extends across 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, if the recess in the first thermoplastic intermediate layer is formed as an opening, no material of the first thermoplastic intermediate layer is arranged in the region of the recess in the layer stack.

[0046] In a further embodiment of the method according to the invention, at least one venting channel is formed by a recess in the second thermoplastic intermediate layer, which extends from the venting path network to a side edge of the layer stack. Optionally, the layer stack in this embodiment can additionally comprise 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.

[0047] The recess in the second thermoplastic intermediate layer is preferably between 1 mm and 5 mm wide, particularly preferably between 2 mm and 3 mm. It is understood that the length of the recess corresponds to the distance from the venting path network to a side edge of the layer stack.

[0048] The recess in the second thermoplastic intermediate layer is preferably formed as an opening, i.e., the recess extends across 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, if the recess in the second thermoplastic intermediate layer is formed as an opening, no material of the second thermoplastic intermediate layer is arranged in the layer stack in the region of the recess.

[0049] 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 closest to the transition from the venting channel to the venting path network. Such a venting channel can run linearly, curved, or meandering, with even more complex shapes preferably having a main direction perpendicular to the nearest side edge of the layer stack.

[0050] It is understood that the recess for a venting channel formed as a recess in the first, second, or third thermoplastic intermediate layer is introduced into the first, second, or third thermoplastic intermediate layer after or during the cutting of the intermediate layer from a roll of thermoplastic intermediate layer to form a first, second, or third thermoplastic intermediate layer in a size suitable for the layer stack. The recess is therefore not formed during the production of the intermediate layer from a roll of thermoplastic. This ensures the desired positioning of the venting channel formed as a recess in the first, second, or third thermoplastic intermediate layer in the layer stack. The venting channel is thus formed specifically at the desired location.

[0051] In a further embodiment of the method according to the invention, at least one ventilation channel is formed 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, wherein the hole, when viewed through the layer stack, is arranged in a region in which the ventilation path network is arranged. It is understood that in this embodiment, in step b), the layer stack is arranged in a vacuum bag. In embodiments in which the ventilation channel is formed by a hole, the hole is preferably formed in the inner pane and the second thermoplastic intermediate layer. Furthermore, the hole is preferably arranged in a region which, after installation of the composite pane in a vehicle, is concealed by the vehicle body or add-on parts thereto.The diameter of the hole is preferably between 1 mm and 5 mm, particularly preferably between 2 mm and 3 mm.

[0052] In embodiments of the method according to the invention in which a ventilation channel is formed as a hole in the inner pane and the second thermoplastic intermediate layer or as a hole in the outer pane and the first thermoplastic intermediate layer, the method preferably comprises, after step g), an additional method step in which the hole in the inner pane or the outer pane is closed.

[0053] The invention consequently also comprises a method for producing a composite pane with a photovoltaic module, at least comprising the following steps: a) providing a layer stack at least comprising 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 one solar cell and is arranged between the outer pane and the inner pane, the first thermoplastic intermediate layer is arranged 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 regions between the photovoltaic module and the first thermoplastic intermediate layer and / or the second thermoplastic intermediate layer, an intermediate space for air passage is formed such that a ventilation path network is formed,wherein the layer stack has at least one ventilation channel running from the ventilation path 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 a gap for air passage is formed between the photovoltaic module and the third thermoplastic intermediate layer, and the venting path network includes the gap between the third thermoplastic intermediate layer and the photovoltaic module; b) arranging the layer stack in a vacuum bag or arranging a vacuum ring around the layer stack; c) heating the layer stack to a temperature between 30°C and 70°C; d) venting the heated layer stack at a temperature between 30°C and 70°C; e) gradually increasing the temperature to a temperature between 100°C and 130°C to form a vented pre-composite; f) removing the vacuum bag or the vacuum ring; g) lamination of the vented pre-composite in an autoclave,wherein 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 next to one another, and a venting channel is formed between the strips of the fourth thermoplastic intermediate layer, which extends from the venting path network to a side edge of the layer stack, and / or wherein at least one venting channel is formed by a recess formed as an opening in the first thermoplastic intermediate layer,which extends from the venting path network to a side edge of the layer stack and / or at least one venting channel is formed as a recess in the second thermoplastic intermediate layer, which extends from the venting path network to a side edge of the layer stack, and / or at least one venting channel is formed as a recess in the third thermoplastic intermediate layer, which extends from the venting path network to a side edge of the layer stack, and / or wherein at least one venting 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, which, when viewed through the layer stack, is arranged in a region in which the venting path network is arranged,and in step b) the stack of layers is placed in a vacuum bag.,

[0054] The process 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 pane and the inner pane and runs from the venting network to the environment. In such a modified process, the pipe is removed during the gradual increase in temperature to a temperature between 100°C and 130°C to form a vented pre-composite.

[0055] The outer and inner panes are preferably glass panes, particularly preferably made of soda-lime glass, as is common for window panes. However, one or both of the panes can also be made of other types of glass, such as quartz glass, borosilicate glass, or aluminosilicate glass.

[0056] The thicknesses of the outer pane and the inner pane are, independently of one another, preferably from 1.0 mm to 12 mm, particularly preferably from 0.5 mm to 5 mm, very particularly preferably from 1 mm to 3 mm, for example 2.1 mm or 1.6 mm.

[0057] The outer pane and the inner pane can optionally be thermally or chemically toughened, partially toughened or not toughened independently of each other.

[0058] In a preferred embodiment of the method according to the invention, the outer pane and the inner pane are curved in one or more spatial directions, as is usual for motor vehicle windows, in particular roof windows. Typical radii of curvature are in the range from approximately 50 mm to approximately 1200 mm. The radius of curvature does not have to be constant across the entire laminated pane. There may be more or less strongly curved regions. There may also be flat and curved regions. The outer pane and the inner pane may also be flat, for example, if the laminated pane is intended as a pane for buses, trains, tractors, or as building glazing.

[0059] The surface area of ​​the composite pane can vary widely and can therefore be perfectly adapted to individual requirements. For example, the surface area of ​​the composite pane can range from 100 cm 2 up to 5 m 2 preferably 0.5 m 2 up to 3 m 2. The composite pane is preferably a roof pane.

[0060] The area of ​​the photovoltaic module is preferably between 50% and 100% of the area of ​​the composite pane, for example, between 50% and 90%. This is particularly advantageous with regard to the performance of the integrated photovoltaic module and a uniform appearance of the composite pane. The area of ​​the photovoltaic module can, for example, range from 0.1 m 2 up to 5 m 2 , preferably 0.5 m 2 up to 2 m 2 be.

[0061] 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 independently contain or consist independently of a thermoplastic polymer, preferably polyvinyl butyral (PVB), ethylene vinyl acetate (EVA) and / or thermoplastic polyolefin (TPO).

[0062] The first thermoplastic intermediate layer and the second thermoplastic intermediate layer independently preferably have a thickness of 0.2 mm to 2 mm, particularly preferably 0.3 mm to 1 mm, in particular 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 each be 0.76 mm, for example.

[0063] The optionally present third thermoplastic intermediate layer can be 0.38 mm thick, for example. The thickness of the optionally present third thermoplastic intermediate layer preferably corresponds to the thickness of the photovoltaic module. A photovoltaic module, within the meaning of the invention, is a component for generating electrical energy or electrical current using the photovoltaic effect. The photovoltaic module is handled as a single component and preferably has only two electrical connections (two electrical poles, so to speak "plus and minus pole"), via which the component as a whole is electrically contacted. 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 parallel, or there can be groups of serially connected solar cells that are connected in parallel, or groups of parallel-connected solar cells that are connected in series. Serial connection of all solar cells is preferred. The photovoltaic module can also be referred to as a photovoltaic module or solar module. Within the meaning 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 further subdivided structurally. The solar cell can also be referred to as a photovoltaic cell.

[0064] The solar cells of the photovoltaic module are capable of converting sunlight directly into electrical energy. Each solar cell has a photovoltaically active absorber layer between a front electrode and a rear electrode. The front electrode faces the outer pane of the composite pane, and the rear electrode faces the inner pane. The electrodes are typically flat electrodes that cover the entire absorber layer. When sunlight is absorbed, free charge carriers are generated in the absorber layer (photovoltaic effect as a special case of the internal photoelectric effect), which are then conducted via the electrodes to generate electrical energy or an electric current. The absorber layer often contains dopants to optimize the transport of charge carriers to the electrodes.

[0065] In principle, all types of solar cells can be used within the scope of the present invention. There are no restrictions on specific solar cells. In particular:

[0066] - 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 pm to 3 pm; in thick-film cells, the absorber layer has a greater thickness (for example 20 pm to 500 pm); - 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;

[0067] - the crystal structure of the absorber layer can be monocrystalline, polycrystalline or amorphous.

[0068] Thick-film cells, for example, can have an absorber layer based on monocrystalline or polycrystalline silicon. Thin-film cells, for example, can 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 compound from the copper-indium-sulfur / selenium (CIS; e.g., CuInSe2) or a compound from the copper-indium-gallium-sulfur / selenium (CIGS; e.g., Cu(InGa)(SSe)2) group.

[0069] The method according to the invention is particularly advantageous for thick-film cells because they are typically more fragile than thin-film cells.

[0070] The front electrode and the back electrode can, for example, be formed as thin conductive or semiconducting layers with thicknesses of preferably from 50 nm to 2 pm. The layers can contain, for example, metals such as silver, gold, copper, molybdenum, titanium, tungsten, nickel, titanium, chromium, tantalum, aluminum-doped zinc oxide, or transparent conductive oxides such as indium tin oxide. The front electrode and / or the back electrode can, however, also be formed, for example, as a mesh of thin wires containing, for example, aluminum, copper, silver, and / or gold. At least the front electrode is transparent so that sunlight can penetrate the absorber layer. The electrodes can be formed as individual layers or as a stack of several layers.

[0071] In addition to the absorber layer and the electrodes, the solar cell may of course comprise further individual layers known to the person skilled in the art, for example a buffer layer for adapting the electronic properties between the absorber layer and an electrode layer or diffusion barrier layers.

[0072] Before or during 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.

[0073] The outer pane has (at least) one transparent area through which sunlight can pass through the outer pane and excite the photovoltaic module. This transparent area of ​​the outer pane therefore defines an active area of ​​the composite pane. The photovoltaic module is arranged (at least partially, in particular largely or even completely) in the transparent area.

[0074] The outer pane can be transparent overall. However, the outer pane can also have an opaque masking area through which no sunlight can pass and which defines a masking area of ​​the composite pane. The active area then corresponds to the composite pane minus the masking area. Such masking areas are common in vehicle windows. They are typically formed by an opaque cover print on the surface of the outer pane facing the photovoltaic module. An enamel printing paste containing glass frits and a pigment, in particular black pigment, is printed onto the surface, for example using a screen printing process, and then fired. The masking area typically comprises a circumferential edge area of ​​the outer pane and is thus designed like a frame.However, the masking area can also comprise further areas which are designed, for example, as a type of cross bracing of the frame-like edge area.

[0075] Alternatively, a masking region can also be formed by the first thermoplastic intermediate layer being partially opaque.

[0076] It is understood that, in addition to a transparent area in which sunlight can pass through the outer pane and stimulate a photovoltaic module arranged in this area, the composite pane can also have further transparent areas in which, when viewed through the composite pane, the photovoltaic module is not arranged.

[0077] In embodiments, the inner pane and / or the second thermoplastic intermediate layer can be tinted or colored at least in some areas. The outer pane and / or the second thermoplastic intermediate layer can be tinted or colored, for example, in a peripheral edge region. The coloring or tinting can also be applied over the entire surface and, in particular, can be designed such that the photovoltaic module is not visible or is only partially visible to an observer when looking at the inner pane.

[0078] In one embodiment, one of the surfaces of the outer pane is provided with an opaque cover print in a peripheral edge region and / or one of the surfaces of the inner pane is provided with an opaque cover print in a peripheral edge region. However, it is also possible for one of the surfaces of the inner pane to be provided with an opaque cover print not only in a peripheral edge region but over its entire surface, thus making the photovoltaic module invisible to an observer when looking at the inner pane. The opaque cover print is preferably arranged on the surface of the inner pane facing away from the photovoltaic module.

[0079] As described above, according to the invention, the layer stack has at least one venting channel running from the venting path network to the environment. In a particularly preferred embodiment of the method, the layer stack has at least two venting channels running from the venting path network to the environment. If at least two venting channels are present, these are preferably arranged on opposite sides of the layer stack. Consequently, if at least two venting channels formed as recesses in the first intermediate layer, the second intermediate layer, or the third intermediate layer are present, one of the venting channels preferably extends from the venting path network to a first lateral edge of the layer stack, and another of the venting channels extends from the venting path network to a second lateral edge of the layer stack, wherein the first lateral edge is opposite the second lateral edge.In a preferred embodiment of the method, the layer stack has a maximum of eight, particularly preferably a maximum of four, ventilation channels running from the ventilation path network to the environment.

[0080] In a preferred embodiment of the method, 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 percent by weight of iron oxide, preferably less than 0.03 percent by weight of iron oxide.

[0081] According to the invention, a composite pane is also produced according to a method according to the invention.

[0082] The preferred embodiments of the method according to the invention described above also apply accordingly to the composite pane according to the invention.

[0083] During the process according to the invention, as described above, the thermoplastic intermediate layers melt, and the venting channels and the venting network are largely filled with the thermoplastic layers. It is not apparent to the naked eye in the composite pane according to the invention that the layer stack used in the process according to the invention had a venting network and at least one venting channel. However, in the composite pane produced according to the process according to the invention, the at least one venting channel and the venting 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 pane located close to the projection surface, for example, 50 cm.

[0084] The invention further encompasses the use of a composite pane according to the invention as a window pane of 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, in particular as a roof window of a passenger car or truck. The various embodiments of the invention can be implemented individually or in any desired combinations. In particular, the features mentioned above and explained below can be used not only in the specified combinations, but also in other combinations or on their own, without departing from the scope of the present invention.

[0085] The invention is explained in more detail below with reference to drawings. The drawings are schematic representations and not to scale. The drawings do not limit the invention in any way.

[0086] They show:

[0087] Fig. 1 is a flow chart of a method according to the invention,

[0088] Fig. 2 is a plan view of an embodiment of a layer stack,

[0089] Fig. 3 shows a cross section through the layer stack shown in Fig. 2,

[0090] Fig. 4 is a plan view of a further embodiment of a layer stack, Fig. 5 is a plan view of a further embodiment of a layer stack, Fig. 6 is a plan view of a further embodiment of a layer stack, Fig. 7 is a plan view of a further embodiment of a layer stack, Fig. 8 is a plan view of a further embodiment of a layer stack, Fig. 9 is a plan view of a further embodiment of a layer stack, Fig. 10 is a plan view of a further embodiment of a layer stack, Fig. 11 is a plan view of a further embodiment of a layer stack, Fig. 12 is a plan view of a further embodiment of a layer stack, Fig. 13 is a plan view of a further embodiment of a layer stack, Fig. 14 is a plan view of a further embodiment of a layer stack,

[0091] Fig. 15 is an exploded view of the embodiment of a layer stack shown in Fig. 2 and Fig. 3,

[0092] Fig. 16 is an exploded view of the embodiment of a

[0093] layer stack,

[0094] Fig. 17 is an exploded view of the embodiment of a

[0095] layer stack,

[0096] Fig. 18 is an exploded view of the embodiment of a

[0097] Layer stack, Fig. 19 an exploded view of the embodiment of a layer stack shown in Fig. 7,

[0098] Fig. 20 is an exploded view of the embodiment of a layer stack shown in Fig. 8,

[0099] Fig. 21 is an exploded view of the embodiment of a layer stack shown in Fig. 9,

[0100] Fig. 22 is an exploded view of the embodiment of a

[0101] layer stack,

[0102] Fig. 23 is an exploded view of the embodiment of a

[0103] layer stack,

[0104] Fig. 24 is an exploded view of the embodiment of a

[0105] layer stack,

[0106] Fig. 25 is an exploded view of the embodiment of a

[0107] layer stack,

[0108] Fig. 26 is an exploded view of the embodiment of a

[0109] layer stack,

[0110] Fig. 27 is a plan view of another embodiment of a layer stack, and

[0111] Fig. 28 is a plan view of another embodiment of a layer stack.

[0112] Fig. 1 shows a flow diagram of a method according to the invention. In step a) of the method, a layer stack is provided. The layer stack comprises at least one outer pane, a first thermoplastic intermediate layer, a photovoltaic module, a second thermoplastic intermediate layer and an inner pane. 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 arranged 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 some regions between the photovoltaic module and the first thermoplastic intermediate layer and / or the second thermoplastic intermediate layer, an intermediate space for air to pass through is formed in such a way that a ventilation path network is formed.In addition, the layer stack has at least one venting channel which runs from the venting path 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 arranged 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 take place after step b) or simultaneously. Alternatively, step c) can also take place 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 subsequent step f), the vacuum bag or the vacuum ring is removed and in the subsequent step g), the de-aerated pre-composite is laminated in an autoclave, whereby a composite pane according to the invention with a photovoltaic module is obtained.

[0113] Fig. 2 shows a plan view of an embodiment of a layer stack 1, as may be present after step a) of the method according to the invention, and Fig. 3 shows the cross section through the layer stack 1 shown in Fig. 2 along the section line A'-A. Fig. 15 shows the embodiment of the layer stack 1 shown in Fig. 2 and Fig. 3 as an exploded view.

[0114] In the embodiment shown in Figures 2, 3 and 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.

[0115] 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, for example, and the inner pane 6 has a thickness of 2.1 mm. In the installed position, the outer pane 1 faces the outside environment, while the inner pane 2 faces the vehicle interior.

[0116] The first thermoplastic intermediate layer 3 and the second thermoplastic intermediate layer 5 consist, for example, of PVB and each have a thickness of 0.76 mm.

[0117] In the embodiment shown in Figures 2, 3, and 15, the photovoltaic module 4 comprises a solar cell 7. A gap for air passage is formed between the photovoltaic module 4 and the first thermoplastic intermediate layer 3 and the second thermoplastic intermediate layer 5. The gap for air passage is designed such that a ventilation network 8 is formed. In the embodiment shown in Figures 2 and 15, the ventilation network 8 is in the form of a frame surrounding the photovoltaic module 4.

[0118] In the embodiment shown in Figures 2, 3 and 15, the second thermoplastic intermediate layer 5 has a recess 13 through which a venting channel 9 is formed, running from the venting path network 8 to a side edge. The venting channel 9 runs from the venting path network 8 to the side edge and thus to the surroundings of the layer stack 1. In the embodiment shown in Figures 2, 3 and 15, the venting channel 9 runs linearly and essentially perpendicular to the side edge of the layer stack 1 closest to the transition from the venting channel 9 to the venting path network 8. The width of the recess 13 is, for example, 3 mm. In the embodiment shown in Figures 2, 3 and 15, the recess 13 is formed as an opening.

[0119] It is understood that the venting 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.

[0120] 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 venting channel 9 can be formed between the strips of the fourth thermoplastic intermediate layer 12. Also alternatively, the venting channel 9 can be formed as a hole 14 in the inner pane 6 and the second thermoplastic intermediate layer 5, wherein the hole 14, when viewed through the layer stack 1, is arranged in a region in which the venting path network 8 is arranged.

[0121] Fig. 4 shows a plan view of a further embodiment of a layer stack 1, as can be present after step a) of the method according to the invention. In Fig. 16, the embodiment of the layer stack 1 shown in Fig. 4 is shown as an exploded view. In the embodiment shown in Figures 4 and 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.

[0122] 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, for example, and the inner pane 6 has a thickness of 2.1 mm. In the installed position, the outer pane 1 faces the outside environment, while the inner pane 2 faces the vehicle interior.

[0123] The first thermoplastic intermediate layer 3 and the second thermoplastic intermediate layer 5 consist, for example, of PVB and each have a thickness of 0.76 mm.

[0124] In the embodiment shown in Figures 4 and 16, the photovoltaic module 4 comprises nine solar cells 7, wherein a gap for air passage is formed between each two adjacent solar cells 7. In addition, a gap for air passage is formed between the photovoltaic module 4 and the first thermoplastic intermediate layer 3 and the second thermoplastic intermediate layer 5. The gaps for air passage are designed such that a ventilation path network 8 is formed. In the embodiment shown in Figures 4 and 16, the ventilation path 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.

[0125] In the embodiment shown in Figures 4 and 16, the second thermoplastic intermediate layer 5 has a recess 13 through which a venting channel 9 is formed, running from the venting path network 8 to a side edge. The venting channel 9 runs from the venting path network to the side edge and thus to the surroundings of the layer stack 1. In the embodiment shown in Figures 4 and 16, the venting channel 9 runs linearly and essentially perpendicular to the side edge of the layer stack 1 closest to the transition from the venting channel 9 to the venting path network 8. The width of the recess 13 is, for example, 3 mm. In the embodiment shown in Figures 4 and 16, the recess 13 is formed as an opening.It is understood that the venting 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.

[0126] Fig. 5 shows a plan view of another embodiment of a layer stack 1, as may be present after step a) of the method according to the invention. Fig. 17 shows the embodiment of the layer stack 1 shown in Fig. 5 as an exploded view.

[0127] The embodiment of the layer stack 1 shown in Figures 5 and 17 differs from that shown in Figures 4 and 16 only in that the venting channel 9 is not formed as a recess 13 in the second thermoplastic intermediate layer 5, but rather, 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 are arranged next to one another, and the venting 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 venting path network 8 to the side edge of the layer stack 1.The strips of the fourth thermoplastic intermediate layer 12 are arranged substantially parallel to each other, and the shortest distance between the two strips is, for example, 3 mm. The fourth thermoplastic intermediate layer 12 is made of PVB, for example.

[0128] Fig. 6 shows a plan view of another embodiment of a layer stack 1, as may be present after step a) of the method according to the invention. Fig. 18 shows the embodiment of the layer stack 1 shown in Fig. 6 as an exploded view.

[0129] The embodiment of the layer stack 1 shown in Figures 6 and 18 differs from that shown in Figures 4 and 16 only in that the venting channel 9 is not formed as a recess 13 in the second thermoplastic intermediate layer 5, but rather by a hole 14 in the inner pane 6 and the second thermoplastic intermediate layer 5, wherein the hole 14, when viewed through the layer stack 1, is arranged in an area in which the venting path network 8 is arranged. The hole 14 has, for example, a diameter of 3 mm. It is understood that in this embodiment, the layer stack 1 is arranged in a vacuum bag in step b) of the method according to the invention.

[0130] In addition, it is understood that the hole 14 can also be formed in the outer pane 2 and the first thermoplastic intermediate layer 3 instead of in the inner pane 6 and the second thermoplastic intermediate layer 5, although this is not preferred.

[0131] Fig. 7 shows a plan view of another embodiment of a layer stack 1, as may be present after step a) of the method according to the invention. Fig. 19 shows the embodiment of the layer stack 1 shown in Fig. 7 as an exploded view.

[0132] In the embodiment shown in Figures 7 and 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 in which the photovoltaic module 4 is received, so that the third thermoplastic intermediate layer 10 surrounds the photovoltaic module 4 in a frame-like manner.

[0133] 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, for example, and the inner pane 6 has a thickness of 2.1 mm. In the installed position, the outer pane 1 faces the outside environment, while the inner pane 2 faces the vehicle interior.

[0134] The first thermoplastic intermediate layer 3 and the second thermoplastic intermediate layer 5 are made, for example, of PVB and each have a thickness of 0.76 mm. The third thermoplastic intermediate layer 10 is made, for example, of PVB and has a thickness of 0.38 mm. The third thermoplastic intermediate layer 10 preferably has a thickness that corresponds to the thickness of the photovoltaic module 4. In the embodiment shown in Figures 7 and 19, the photovoltaic module 4 comprises nine solar cells 7, with a gap for air passage being formed between each two adjacent solar cells 7. In addition, a gap for air passage is formed between the photovoltaic module 4 and the first thermoplastic intermediate layer 3 and the second thermoplastic intermediate layer 5. The gaps for air passage are designed such that a ventilation path network 8 is formed.In the embodiment shown in Figures 7 and 19, the recess 11 in the third thermoplastic intermediate layer 10 is larger than the photovoltaic module 4, so that a gap for air passage is formed between the photovoltaic module 4 and the third thermoplastic intermediate layer 10, and the ventilation network 8 also encompasses the gap between the third thermoplastic intermediate layer 10 and the photovoltaic module 4. In the embodiment shown in Figures 7 and 19, the ventilation network 8 thus 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.

[0135] In the embodiment shown in Figures 7 and 19, the third thermoplastic intermediate layer 10 has a recess 13 through which a venting channel 9 is formed, running from the venting path network 8 to a side edge. The venting channel 9 runs from the venting path network 8 to the side edge and thus to the surroundings of the layer stack 1. In the embodiment shown in Figures 7 and 19, the venting channel 9 runs linearly and essentially perpendicular to the side edge of the layer stack 1 closest to the transition from the venting channel 9 to the venting path network 8. The width of the recess 13 is, for example, 3 mm. In the embodiment shown in Figures 7 and 19, the recess 13 is designed in the form of an opening.

[0136] Fig. 8 shows a plan view of another embodiment of a layer stack 1, as may be present after step a) of the method according to the invention. Fig. 20 shows the embodiment of the layer stack 1 shown in Fig. 8 as an exploded view.

[0137] The embodiment of the layer stack 1 shown in Figures 8 and 20 differs from that shown in Figures 7 and 19 only in that the venting 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.

[0138] It is understood that the venting 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.

[0139] Fig. 9 shows a plan view of another embodiment of a layer stack 1, as may be present after step a) of the method according to the invention. Fig. 21 shows the embodiment of the layer stack 1 shown in Fig. 9 as an exploded view.

[0140] The embodiment of the layer stack 1 shown in Figures 9 and 21 differs from that shown in Figures 7 and 19 only in that the venting channel 9 is not formed as a recess 13 in the third thermoplastic intermediate layer 10, but rather, in the layer stack 1, between the third thermoplastic intermediate layer 10 and the second thermoplastic intermediate layer 5, two strips of a fourth thermoplastic intermediate layer 12 are arranged next to one another, and the venting 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 venting path network 8 to the side edge of the layer stack 1.The strips of the fourth thermoplastic intermediate layer 12 are arranged substantially parallel to each other, and the shortest distance between the two strips is, for example, 3 mm. The fourth thermoplastic intermediate layer 12 is made of PVB, for example.

[0141] It is understood that the two 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 venting channel 9 is arranged between the first thermoplastic intermediate layer 3 and the third thermoplastic intermediate layer 10. Fig. 10 shows a plan view of a further embodiment of a layer stack 1, as may be present after step a) of the method according to the invention. In Fig. 22, the embodiment of the layer stack 1 shown in Fig. 10 is shown as an exploded view.

[0142] The embodiment of the layer stack 1 shown in Figures 10 and 22 differs from that shown in Figures 7 and 19 only in that the venting channel 9 is not formed as a recess 13 in the third thermoplastic intermediate layer 10, but rather by a hole 14 in the inner pane 6 and the second thermoplastic intermediate layer 5. When viewed through the layer stack 1, the hole 14 is located in a region in which the venting path network 8 is located. The hole 14 has, for example, a diameter of 3 mm.

[0143] It is understood that in this embodiment, the layer stack 1 is arranged in a vacuum bag in step b) of the method according to the invention.

[0144] In addition, it is understood that the hole 14 can also be formed in the outer pane 2 and the first thermoplastic intermediate layer 3 instead of in the inner pane 6 and the second thermoplastic intermediate layer 5, although this is not preferred.

[0145] Fig. 11 shows a plan view of another embodiment of a layer stack 1, as may be present after step a) of the method according to the invention. Fig. 23 shows the embodiment of the layer stack 1 shown in Fig. 11 as an exploded view.

[0146] The embodiment of the layer stack 1 shown in Figures 11 and 23 differs from that shown in Figures 7 and 19 only in that the recess 11 in the third thermoplastic intermediate layer 10 corresponds in terms of its external dimensions to the dimensions of the photovoltaic module 4.

[0147] Fig. 12 shows a plan view of another embodiment of a layer stack 1, as may be present after step a) of the method according to the invention. Fig. 24 shows the embodiment of the layer stack 1 shown in Fig. 12 as an exploded view.

[0148] The embodiment of the layer stack 1 shown in Figures 12 and 24 differs from that shown in Figures 11 and 23 only in that the venting 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.

[0149] It is understood that the venting 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.

[0150] Fig. 13 shows a plan view of another embodiment of a layer stack 1, as may be present after step a) of the method according to the invention. Fig. 25 shows the embodiment of the layer stack 1 shown in Fig. 13 as an exploded view.

[0151] The embodiment of the layer stack 1 shown in Figures 13 and 25 differs from that shown in Figures 11 and 23 only in that the venting channel 9 is not formed as a recess 13 in the third thermoplastic intermediate layer 10, but rather, in the layer stack 1, between the third thermoplastic intermediate layer 10 and the second thermoplastic intermediate layer 5, two strips of a fourth thermoplastic intermediate layer 12 are arranged next to one another, and the venting 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 venting path network 8 to the side edge of the layer stack 1.The strips of the fourth thermoplastic intermediate layer 12 are arranged substantially parallel to each other, and the shortest distance between the two strips is, for example, 3 mm. The fourth thermoplastic intermediate layer 12 is made of PVB, for example.

[0152] It is understood that the two 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 venting channel 9 is arranged between the first thermoplastic intermediate layer 3 and the third thermoplastic intermediate layer 10. Fig. 14 shows a plan view of a further embodiment of a layer stack 1, as may be present after step a) of the method according to the invention. In Fig. 26, the embodiment of the layer stack 1 shown in Fig. 14 is shown as an exploded view.

[0153] The embodiment of the layer stack 1 shown in Figures 14 and 26 differs from that shown in Figures 11 and 23 only in that the venting channel 9 is not formed as a recess 13 in the third thermoplastic intermediate layer 10, but rather by a hole 14 in the inner pane 6 and the second thermoplastic intermediate layer 5. When viewed through the layer stack 1, the hole 14 is located in a region in which the venting path network 8 is located. The hole 14 has, for example, a diameter of 3 mm.

[0154] It is understood that in this embodiment, the layer stack 1 is arranged in a vacuum bag in step b) of the method according to the invention.

[0155] In addition, it is understood that the hole 14 can also be formed in the outer pane 2 and the first thermoplastic intermediate layer 3 instead of in the inner pane 6 and the second thermoplastic intermediate layer 5, although this is not preferred.

[0156] Fig. 27 shows a plan view of another embodiment of a layer stack 1, as may be present after step a) of the method according to the invention. The embodiment of the layer stack 1 shown in plan view in Fig. 27 differs from that shown in Fig. 4 only in that the second thermoplastic intermediate layer 5 has not just one recess 13, but two recesses 13. Thus, the layer stack shown in Fig. 27 has two venting channels 9, wherein the two venting channels 9 are arranged on opposite sides of the layer stack 1.

[0157] Fig. 28 shows a plan view of another embodiment of a layer stack 1, as may be present after step a) of the method according to the invention. The embodiment of the layer stack 1 shown in plan view in Fig. 28 differs from that shown in Fig. 7 only in that the third thermoplastic intermediate layer 10 has not just one recess 13, but two recesses 13. Thus, the layer stack shown in Fig. 28 has two venting channels 9, wherein the two venting channels 9 are arranged on opposite sides of the layer stack 1.

[0158] It is understood that the embodiments shown in Figs. 2, 5, 6, and 8 to 14 can also be modified such that the layer stack 1 has more than one venting channel 9, wherein the venting channels 9 can also be formed in different layers of the layer stack 1.

[0159] In the figures, the composite pane, the outer pane, and the inner pane are each shown as flat. It is understood that the composite pane, the outer pane, and the inner pane can be flat or curved. The composite pane, the outer pane, and the inner pane are preferably each curved.

[0160] For the sake of simplicity, the photovoltaic module's electrical connections, such as connectors between the solar cells when more than one solar cell is present or bus bars, are not shown in the figures. These connections can be used, for example, to interconnect the solar cells and connect the photovoltaic module to the vehicle's on-board electrical system, for example, to charge the vehicle battery.

[0161] List of reference symbols:

[0162] 1 layer stack

[0163] 2 Outer pane 3 First thermoplastic intermediate layer

[0164] 4 photovoltaic modules

[0165] 5 second thermoplastic intermediate layer

[0166] 6 inner pane

[0167] 7 Solar cell 8 Ventilation network

[0168] 9 Ventilation duct

[0169] 10 third thermoplastic intermediate layer

[0170] 11 Recess

[0171] 12 fourth thermoplastic intermediate layer 13 recess

[0172] 14 holes

[0173] A'-A intersection line

Claims

Patent claims 1. A method for producing a composite pane with a photovoltaic module (4), comprising at least the following steps: a) providing a layer stack (1) comprising at least one 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 regions between the photovoltaic module (4) and the first thermoplastic intermediate layer (3) and / or the second thermoplastic intermediate layer (5), a gap for air passage is formed in such a way thatthat a venting path network (8) is formed, and the layer stack (1) has at least one venting channel (9) extending from the venting path network (8) to the environment; b) arranging the layer stack (1) in a vacuum bag or arranging a vacuum ring around the layer stack (1); c) heating the layer stack (1) to a temperature between 30°C and 70°C; d) venting the heated layer stack (1) at a temperature between 30°C and 70°C; e) gradually increasing the temperature to a temperature between 100°C and 130°C to form a vented pre-composite; f) removing the vacuum bag or the vacuum ring; g) lamination of the vented pre-composite in an autoclave.

2. Method according to claim 1, wherein the photovoltaic module (4) comprises at least two solar cells (7) and between each two adjacent solar cells (7) there is formed an intermediate space for the passage of air, which space is also encompassed by the ventilation path network (8).

3. The method according to claim 1 or 2, wherein the layer stack (1) additionally has 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 intermediate space for air to pass through is formed between the photovoltaic module (4) and the third thermoplastic intermediate layer (10), and the ventilation path network (8) also includes the intermediate space between the third thermoplastic intermediate layer (10) and the photovoltaic module (4).

4. The method according to claim 3, wherein at least one venting channel (9) is formed by a recess (13) in the third thermoplastic intermediate layer (10) which extends from the venting path network (8) to a side edge of the layer stack (1).

5. The method according to claim 3 or 4, wherein two strips of a fourth thermoplastic intermediate layer (12) are arranged next to one another 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 venting channel extends from the venting path network (8) to a side edge of the layer stack (1).

6. The method according to claim 1 or 2, wherein two strips of a fourth thermoplastic intermediate layer (12) are arranged next to one another 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 venting channel extends from the venting path network to a side edge of the layer stack (1).

7. Method according to one of claims 1 to 6, wherein at least one venting channel (9) is formed by a recess (13) in the first thermoplastic intermediate layer (3), which extends from the venting path network (8) to a side edge of the layer stack (1) and / or at least one venting channel (9) is formed as a recess (13) in the second thermoplastic intermediate layer (5), which extends from the ventilation path network (8) to a side edge of the layer stack (1).

8. The method according to claim 7, wherein the recess (13) in the first thermoplastic intermediate layer (3) and / or the recess (13) in the second thermoplastic intermediate layer (5) is formed as an opening.

9. The method according to any one of claims 1 to 8, wherein at least one venting channel (9) is formed through a hole (14) in the inner pane (6) and the second thermoplastic intermediate layer (5) or through a hole (14) in the outer pane (2) and the first thermoplastic intermediate layer (3), which, when viewed through the layer stack (1), is arranged in a region in which the venting path network (8) is arranged, and in step b) the layer stack (1) is arranged in a vacuum bag.

10. Method according to one of claims 1 to 9, wherein the outer pane (2) and the inner pane (6) are curved and / or wherein the first thermoplastic intermediate layer (2), the second thermoplastic intermediate layer (5), the third thermoplastic intermediate layer (10) and / or the fourth thermoplastic intermediate layer (12) independently of one another contain or consist of polyvinyl butyral (PVB), ethylene vinyl acetate (EVA) and / or thermoplastic polyolefin (TPO) and / or wherein the outer pane (2) has a lower iron content than the inner pane (6).

11. Method according to one of claims 1 to 10, wherein the layer stack (1) has at least two ventilation channels (9) running from the ventilation path network (8) to the environment.

12. Method according to one of claims 1 to 11, wherein the layer stack (1) has a maximum of eight, preferably a maximum of four, particularly preferably a maximum of two ventilation channels (9) running from the ventilation path network (8) to the environment.

13. Method according to one of claims 1 to 12, wherein the inner pane (6) and / or the second thermoplastic intermediate layer (5) is tinted or colored at least in some areas and / or wherein one of the surfaces of the outer pane (2) is provided with an opaque cover print in a peripheral edge area and / or a the surfaces of the inner pane (6) are provided with an opaque cover print in a peripheral edge area or over the entire surface.

14. A composite pane produced by a process according to any one of claims 1 to 13.

15. Use of a composite pane according to claim 14 as a window pane of means of transport for land, air or water traffic, preferably as a windscreen, side window, rear window or roof window of a vehicle, in particular as a roof window of a passenger car or lorry.

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