Method for manufacturing a solar module comprising a photovoltaic structure

The method addresses the challenge of manufacturing solar modules with integrated photovoltaic structures and polymer bodies by using an injection molding process where the electrical connector performs a compensation movement, ensuring it remains accessible and uncovered by polymer, thus enabling efficient and reliable solar module production.

WO2025068475A1PCT designated stage expired Publication Date: 2025-04-03SONO MOTORS GMBH
View PDF 4 Cites 0 Cited by

Patent Information

Application Number
PCT/EP2024/077241
Authority / Receiving Office
WO · WO
Patent Type
Applications
Current Assignee / Owner
Priority Date
2023-09-29
Filing Date
2024-09-27
Publication Date
2025-04-03

AI Technical Summary

Technical Problem

The challenge lies in manufacturing solar modules with integrated photovoltaic structures and polymer bodies, where the electrical connector must remain accessible for connection to electric components without being covered by the polymer structure.

Method used

The method involves using an injection molding machine with a mold, where the electrical connector performs a compensation movement during the mold's closing movement, ensuring it remains accessible and uncovered by polymer, thus eliminating the need for additional steps to uncover the connector.

Benefits of technology

This approach allows for the easy and reliable manufacturing of solar modules with integrated photovoltaic structures and polymer bodies, ensuring the electrical connector remains accessible for connection to vehicle components.

✦ Generated by Eureka AI based on patent content.

Smart Images

  • Figure EP2024077241_03042025_PF_FP_ABST
    Figure EP2024077241_03042025_PF_FP_ABST
Patent Text Reader

Abstract

The invention relates to a Method for manufacturing a solar module (3) comprising a photovoltaic structure (4), on which a polymer structure (5) is molded, placing the photovoltaic structure (4) into the mold (7) of the injection molding machine (6), wherein the mold (7) is in an open position such that the photovoltaic structure (4) can be placed within the mold (7), performing an injection procedure for manufacturing the polymer structure (5) onto the photovoltaic structure (4), wherein during the injection procedure the mold (7) performs a closing movement and a polymer is injected into the mold (7) such that the polymer covers the photovoltaic structure (4).
Need to check novelty before this filing date? Find Prior Art

Description

[0001] Method for manufacturing a solar module comprising a photovoltaic structure

[0002] The present invention relates to a method for manufacturing a solar module comprising a photovoltaic structure according to claim 1 , to a solar module for a solar body panel of a vehicle according to claim 3 and to a solar body panel for a vehicle according to claim 5.

[0003] Nowadays, solar modules generally have a wide range of different applications. The present focus within this application however lies on solar modules, which are used for electric vehicles or with combustion engine vehicles with a battery. An electric vehicle might be equipped with several solar modules for self-charging reasons. A combustion engine vehicle might be equipped accordingly for charging the battery, which is used for electrical consumers of the car. During a ride or while parking, the solar modules enable to generate electric energy from the sun and charge a battery of the vehicle. For electric vehicles, this kind of charging might be applied instead of or additionally to traditional charging of electric vehicles via a power supply or the like. The main advantage of using solar modules in the electric vehicle is to extend the range of the vehicle by adding extra power to the battery. Solar modules can also help to reduce the environmental impact of the vehicle by using a clean, renewable energy source.

[0004] While in general, solar modules might be directly attached to a common body of the vehicle, it was recently found that it can be very beneficial, if the solar modules are more integrated in the body of the vehicle. Thus, at least a solar module or several solar modules is or are comprised by, in particular is or are integrated into, a solar body panel, which may be attached to a part of the body of the vehicle or which may itself form a part of the body of the vehicle, for example a roof, a door or a hood. Beside the solar module or solar modules, the solar body panel comprises a polymer body, which can basically form the shape of the respective part of the body. The polymer body may be formed by a polymer structure of the solar module or by polymer structure of the solar modules. Each solar module thus comprises - beside a photovoltaic structure for converting solar power to electrical power - the polymer structure. The polymer structure is molded onto the photovoltaic structure during manufacturing of the solar modules. While in general, methods for molding polymers might be known for several applications, manufacturing of the solar module, in particular manufacturing of the polymer structure onto the photovoltaic structure, might be challenging with regard to the connectivity of the solar module. For connecting the photovoltaic structure to an electric component, such as a junction box, of the vehicle at least one of the solar modules, particularly each solar module, comprises an electric connector. The electric connector is attached to the photovoltaic structure on the same side as the polymer structure is molded to the photovoltaic structure. Thus, it has to be ensured that, after manufacturing of the polymer structure onto the photovoltaic structure, the electric connector is accessible such that the solar module can be connected to the electric component.

[0005] The invention is based on the problem of providing a method, with which a solar module comprising a photovoltaic structure, a polymeric structure and an electric connector can be easily and reliably manufactured.

[0006] The above-noted object is solved by the features of claim 1 .

[0007] The main realization of the present invention is that a solar module is manufactured by injection molding using an injection molding machine with a mold, wherein during an injection procedure an electrical connector of the solar module performs a compensation movement, which is caused by a closing movement of the mold. Due to the compensation movement of the electrical connector, it is ensured that the mold can be moved, namely closed, wherein the closing movement is not hindered by the electrical connector. Furthermore, it is ensured that the electrical connector, which extends at least partly through a polymer structure of the solar module, is at least partly not covered by polymer after the injection procedure is performed such that an electric component, such as a junction box, of the vehicle is connectable to the electrical connector. As it can be understood, further work steps for partly uncovering the electrical connector from polymer or rather polymer structure, as these are necessary in known methods for manufacturing solar modules, are not necessary for the present invention. Thus, a solar module comprising a photovoltaic structure, a polymeric structure and an electric connector can be easily and reliably manufactured by the present invention.

[0008] Proposed is a method for manufacturing a solar module comprising a photovoltaic structure, on which a polymer structure is molded, wherein the method comprises using an injection molding machine with a mold, attaching an electrical connector, in particular comprising or being a spring conductor, to a photovoltaic structure, placing the photovoltaic structure into the mold of the injection molding machine, wherein the mold is in an open position such that the photovoltaic structure can be placed within the mold, and performing an injection procedure for manufacturing the polymer structure onto the photovoltaic structure, wherein during the injection procedure the mold performs a closing movement, in particular such that a polymer can be injected into the mold, and the polymer is injected into the mold such that the polymer covers the photovoltaic structure and the electrical connector at least partly, wherein during the injection procedure the electrical connector being attached to the photovoltaic structure performs a compensation movement, in particular a spring movement, wherein the compensation movement is caused by the closing movement of the mold, wherein during the compensation movement the electrical connector at least partly moves relatively to the photovoltaic structure.

[0009] According to one embodiment it is proposed that the injection procedure is an injection compression procedure and wherein the closing movement comprises an initial closing phase, in which the mold is moved into an initial injection position, that in the initial injection position the polymer is at least partly injected into the mold, and / or, that the closing movement comprises a compression closing phase, in which the mold is further moved into a compression injection position and the injected polymer is compressed inside the mold. The injection compression procedure might be performed by known compression molding machines. Thus, new development of respective machines might be not needed. Furthermore, by using the injection compression procedure, a consistent quality of polymer structures for several solar modules might be ensured. The compensation movement is caused by the closing movement of the mold. Here it is possible, that the movement during the initial closing phase and / or that the movement during the compression closing phase causes the compensation movement of the electrical connector. Since the compensation movement is caused by the closing movement of the mold, which is present in the injection compression procedure anyway, the overall method may be kept simple, in particular since an additional process step for compensation movement can be avoided.

[0010] Another teaching, which is of equal importance, relates to a solar module for a solar body panel of a vehicle, wherein the solar module comprises a photovoltaic structure and a polymer structure, wherein the polymer structure is molded onto the photovoltaic structure, and an electrical connector for connecting the photovoltaic structure to an electric component, such as a junction box, of the vehicle, wherein the electrical connector fully extends from the photovoltaic structure through the polymer structure, wherein the electrical connector on its one end concludes with the outer surface of the polymer structure, in particular the outer surface which is averted with regard to the photovoltaic structure, such that an electrical junction is formed. The solar module might be manufactured by the proposed method.

[0011] All explanations given with regard to the method are fully applicable and vice versa.

[0012] According to one embodiment it is proposed that the electrical connector comprises or being a spring conductor, preferably, that the spring conductor is designed at least in sections, in particular fully, as a plane spring conductor, and / or, that the spring conductor is designed as one piece, and / or, that the spring conductor is made out of bare metal, and / or, that the spring conductor comprises a longitudinal section, which is double-eight-shaped, Z-shaped or 3-shaped. Double-eight-shaped here means that the spring conductor has three circular or oval holes in a row if viewed from a side, the middle circle or oval forming part of two eight-shaped bodies, the outer circles therefore forming part of only one eight each. The spring conductor may be able to perform a spring movement as the compensation movement, for example during manufacturing. During the spring movement, the spring conductor might be deflected from its neutral condition into a compressed condition. The spring conductor is easy to manufacture, if designed at least in sections, preferably completely, as a plane spring conductor. The spring conductor is easy to handle, when assembling the solar module. If the spring conductor is made out of bare metal, and particularly is free of insulating material, the cost of manufacturing might be reduced. Here, insulating material may be not necessary at all, since the polymer structure might function as an insulator. Optionally, the spring conductor may also be coated. A double-eight-shaped, Z-shaped or 3-shaped longitudinal section of the spring conductor may provide improved spring movement abilities.

[0013] Another teaching, which is of equal importance, relates to a solar body panel for a vehicle, wherein the solar body panel comprises a solar module, wherein the solar module is designed as proposed.

[0014] All explanations given with regard to the method and the solar module are fully applicable and vice versa.

[0015] In the following, embodiments of the invention are explained with respect to the drawing. The drawing shows in

[0016] Fig. 1 , a vehicle with a solar body panel, wherein the solar body panel comprises several proposed solar modules,

[0017] Fig. 2, schematically different steps of the proposed method, wherein in a) a mold of an injection molding machine is in an open position and a photovoltaic structure is placed in the mold, in b) the mold is moved to an initial injection position and polymer is injected into the mold and covers the photovoltaic structure and in c) the polymer is compressed and

[0018] Fig. 3, a section of the solar module of fig. 1 comprising the photovoltaic structure, the polymer structure and an electric connector in a) without and in b) with a connection to an electric component of the vehicle.

[0019] Fig. 1 shows a solar body panel 1 for a vehicle 2, here and preferably an electric vehicle 2. The solar body panel 1 relates to the vehicle 2, which is also shown. Here, the vehicle 2 is a car, but might be alternatively a bus, a truck, a boat, a plane or a train. The solar module 3 may be used for charging a main battery of the electric vehicle 2 or for charging a battery of a combustion engine vehicle 2, in particular of a bus or truck. Here and preferably, the solar body panel 1 forms a part of a body of the vehicle 2. As it is shown, the solar body panel 1 forms a roof of the vehicle 2, however, the solar body panel 1 may alternatively form a door or a hood of the vehicle 2 or a part of the roof, a door or a hood of the vehicle 2. It is generally possible, that the solar body panel 1 does not form a part of the body itself, but is attached to a part of the body, for example a roof, a hood or a door, instead. The solar body panel 1 comprises a solar module 3 or, according to Fig. 1 , several solar modules 3. Figures 3a) and 3b) each show a section of such a solar module 3, which is described in more detail later on.

[0020] By now, proposed is a method for manufacturing the solar module 3 comprising a photovoltaic structure 4 on which a polymer structure 5 is molded. The method, which can be best understood in view of figures 2a), 2b) and 2c), comprises using an injection molding machine 6 with a mold 7. The mold 7 may be designed at least two-sectional such that sections of the mold 8 can be moved relatively to each other during manufacturing of the solar module 3. Here and preferably, the method is a method of manufacturing a solar body panel 1 .

[0021] The method further comprises attaching an electrical connector 9 to a photovoltaic structure 4. The electrical connector 9 may comprise or may be a spring conductor 10. A spring conductor 10 is able to perform spring movements, due to its elasticity, and likewise conduct electricity. The method furthermore comprises placing the photovoltaic structure 4 into the mold 7 of the injection molding machine 6. Generally, it is preferred that attaching of the electrical connector 9 takes place before placing the photovoltaic structure 4 including the attached electrical connector 9 into the mold 7. However, it is also possible that the photovoltaic structure 4 is placed in the mold 7 and the electrical connector 9 is attached to the photovoltaic structure 4 thereafter. For placing the photovoltaic structure 4 into the mold 7, the mold 7 is in an open position (fig. 2a)) such that the photovoltaic structure 4 can be placed within the mold 7, as shown in fig. 2a). Attachment of the electrical connector 9 to the photovoltaic structure 4 may comprise soldering. The photovoltaic structure 4 may, like here, comprise at least one conductor track 11 , wherein the electrical connector 9 is attached to the conductor track 11 particularly.

[0022] After attachment of the electrical connector 9 and placement of the photovoltaic structure 4, the method comprises performing an injection procedure for manufacturing the polymer structure 5 onto the photovoltaic structure 4. During the injection procedure the mold 7 performs a closing movement, wherein the open mold 7 (fig. 2a)) is closed (figures 2b) and 2c)), and the polymer is injected into the mold 7 such that the polymer covers the photovoltaic structure 4 and the electrical connector 9 at least partly. The polymer can form the polymer structure 5 of the solar module 3, in particular when the injection procedure is completed.

[0023] During the injection procedure the electrical connector 9 being attached to the photovoltaic structure 4 performs a compensation movement, in particular a spring movement, wherein the compensation movement is caused by the closing movement of the mold 7. During the closing movement, the spring conductor 10 might be compressed. As it can be seen in figures 2a), 2b) and 2c), when the mold 7 performs the closing movement, the closing movement itself causes the electrical connector 9 to perform a compensation movement. Here and preferably, during the closing movement of the mold 7, the sections of the mold 8 are moved relatively to each other. In a compressed condition of the spring conductor 10, the spring conductor 10, due to its spring forces, presses against the mold 7 such that the injected polymer does not break the contact between the spring connector and the mold 7. Therefore, after molding, part of the spring conductor 10 stays uncovered from polymer.

[0024] The electrical connector 9, which is here and preferably the spring conductor 10, performs the compensation movement, which is here and preferably the spring movement, such as the mold 7 contacts and moves, in particular compresses, the electrical connector 9. As a result, during the compensation movement, the electrical connector 9 at least partly moves relatively to the photovoltaic structure 4. When looking at figures 2a), 2b) and 2c), for example, one end 12 of the electrical connector 9, which is averted to the photovoltaic structure 4, moves relatively to the photovoltaic structure 4 due to the compensation movement. It is preferred that the one end 12 of the electrical connector 9, which is averted to the photovoltaic structure 4, moves at least 1 mm, preferably 2 mm, more preferably 3 mm and / or at most 8 mm, preferably at most 7 mm, more preferably at most 6 mm, relatively to the photovoltaic structure 4 due to the compensation movement, as it can be seen for example in figures 2a), 2b) and 2c).

[0025] During the spring movement the spring conductor 10 might be compressed. Here and preferably the spring movement comprises at least a compression of the spring conductor 10 of 1 mm, preferably 2 mm, further preferably 3 mm, relating to the neutral condition of the spring conductor 10. Here and preferably, the electrical connector 9, in particular the spring conductor 10, affects a compressive force on the mold 7, wherein, in particular, the compressive force arises during the compensation movement, in particular during the spring movement. The compressive force is particularly at least 0,1 N.

[0026] Generally, when the mold 7 performs the closing movement, the mold 7 contacts the electrical connector 9, in particular the spring conductor 10, and causes the compensation movement, in particular the spring movement. Due to the contact of the electrical connector 9, in particular of the spring conductor 10, and the mold 7 the polymer is hindered to cover at least a part, in particular a surface, of the electrical connector 9, in particular of the spring conductor 10. The part of the electrical connector 9, in particular the part of the spring conductor 10, which is not covered by polymer and thus polymer-free, may form an electrical junction 13. Here, an electrical connection to an electric component 14 of the vehicle 2 may be formed by soldering or the like.

[0027] Generally, all kinds of injection procedures are performable within the proposed method for manufacturing the solar module 3. However, according to one preferred embodiment it is proposed that the injection procedure is an injection compression procedure. The injection compression procedure may be performed using an injection compression molding machine, which are known in the art. Here and preferably, the closing movement comprises an initial closing phase, in which the mold 7 is moved to an initial injection position, which is exemplarily shown in fig. 2b). The mold 7 might be in the open position (fig. 2a)), particularly before the closing movement is performed, and might be moved from the open position to the initial injection position during the initial closing phase of the closing movement. In the initial injection position, the polymer is at least partly injected into the mold 7. Here and preferably, the mold 7 being in the initial injection position is closed such that an injection section 15 inside the mold 7 is formed, which is closed with regard to the environment. However, it is also possible that the mold 7 being in the initial injection position is semi-opened and an injection section 15 inside the mold 7 is not fully closed with regard to the environment.

[0028] Alternatively or additionally to the initial injection position, the closing movement comprises a compression closing phase, which is exemplarily shown in fig. 2c). In the compression closing phase the mold 7 is further moved to a compression injection position (fig. 2c)) and the injected polymer is compressed inside the mold 7. In reaction to the compression, the injected polymer flows into remaining cavities until being evenly spread through the mold 7. The mold 7 is particularly moved from its initial injection position (fig. 2b)) to the compression injection position (fig. 2c)). Here and preferably, the mold 7 being in the compression injection position is closed and the injected polymer is compressed inside the mold 7, in particular inside the injection section 15.

[0029] With regard to the compensation movement of the electrical connector 9, it is preferred that the compensation movement is performed in the initial closing phase and the compression closing phase, as it can be seen in the figures 2a), 2b) and 2c). However, it is also possible that the compensation movement is performed in the compression closing phase alone. Here, the mold 7 may not contact the electrical connector 9 in its initial injection position, but may contact the electrical connector 9, when the closing movement is further performed and the mold 7 is moved to its compression injection position. It is possible that the closing movement is a continuous movement of the mold 7 or a discontinuous movement of the mold 7, wherein particularly the closing movement is temporarily paused and continued thereafter. For example, the initial closing phase of the closing movement may be performed and the closing movement is stopped temporarily, wherein the mold 7 is in the initial closing position (fig. 2b)). After the polymer is injected at least partially, the closing movement is continued and the compression closing phase of the closing movement is performed accordingly, wherein the mold 7 is moved to the compression injection position (fig. 2c)). Beside the proposed method, another teaching, which is of equal importance, relates to a solar module 3 for a solar body panel 1 of a vehicle 2. The solar module 3 was already described beforehand in context with the proposed method, but however is described in the following in a more general way.

[0030] The solar module 3 comprises a photovoltaic structure 4 and a polymer structure 5, wherein the polymer structure 5 is molded onto the photovoltaic structure 4, as for example shown in figures 3a) and 3b). The photovoltaic structure 4 is able to convert solar power to electrical power. The polymer structure 5 comprises a polymer, in particular a thermoplastic polymer.

[0031] The solar module 3 furthermore comprises an electrical connector 9 for connecting the photovoltaic structure 4 to an electric component 14 of the vehicle 2. Such electric component 14 might be a junction box or the like. The electrical connector 9 may be connected to the photovoltaic structure 4 directly, as shown in figures 3a) and 3b). The electrical connector 9 extends, in particular completely, from the photovoltaic structure 4 through the polymer structure 5. Here and preferably, at least parts of the electrical connector 9 are, in particular directly, covered by the polymer structure 5. The electrical connector 9 on its one end 12 concludes with the outer surface 16 of the polymer structure 5 such that an electrical junction 13 is formed. Here, the one end 12 is averted to the photovoltaic structure 4. It is possible, that on another end of the electrical connector 9 the electrical connector 9 is electrically connected to the photovoltaic structure 4, as also shown in figures 3a), 3b). Preferably, the electrical junction 13 is a surface of the electrical connector 9, in particular the spring connector. The electrical junction 13 is preferably designed plane such that, for example, a plug connector, which relates to the electric component 14 of the vehicle 2, can easily be connected at the electrical junction 13 of the electrical connector 9, as exemplarily shown in fig. 3b). The electrical junction 13 is particularly polymer-free, as it can be seen in fig. 3a). "Polymer-free" in this context comprises that the electrical junction 13 is not covered by polymer, which is injected during the injection procedure. The proposed solar module 3 may be manufactured by the proposed method. For this reason, all explanations given with regard to the method are fully applicable.

[0032] In general, different designs of the electrical connector 9 are thinkable. For example, the electrical connector 9 may comprise a spring connector. However, according to a particularly preferred embodiment it is proposed that the electrical connector 9 is a spring conductor 10, as it can be seen exemplarily in figures 2a), 2b), 2c) as well as 3a), 3b). The spring conductor 10 is preferably embedded at least partly in the polymer structure 5. The spring conductor 10 is preferably preloaded, for example preloaded and embedded at least partly in the polymer structure 5. The spring conductor 10 can, for example, be pre- loaded by compressing the spring conductor 10 and molding the polymer structure 5 onto the photovoltaic structure 4 while the spring conductor 10 is compressed. The spring conductor 10 may be compressible at least in the unassembled condition of the solar module 3, in particular before the polymer structure 5 is molded onto the photovoltaic structure 4. The spring conductor 10 may perform a spring movement during the manufacturing of the solar module 3, wherein during the spring movement the spring conductor 10 may be compressed.

[0033] The spring conductor 10 is preferably designed at least in sections, in particular fully, as a plane spring conductor 10. This might lead to a very easy to manufacture spring conductor 10. The plane spring conductor 10 may comprise a cross section with a small height compared to a broad width. Alternatively or additionally, the spring conductor 10 is designed as one piece. Here and preferably, the spring conductor 10 comprises a longitudinal section, which is double-eight-shaped, Z-shaped, as it is shown in figures 3a), 3b), or 3-shaped. "Longitudinal section" in this context is a cross section alongside the spring conductors 10 longitudinal direction, which can be seen in figures 2a), 2b), 2c). "Double-eight-shaped" in this context means that the longitudinal section of the spring conductors 10 have the shape of two digits "eight", which are arranged on top of each other, wherein the upper circle of the lower eight and the lower circle of the upper eight are the same. Alternatively or additionally, the spring conductor 10 is made out of bare metal. Here and preferably, the spring conductor 10 is free of insulating material. Here, insulating material may be not necessary at all, since the polymer structure 5 might function as an insulator.

[0034] Another teaching, which is of equal importance, relates to a solar body panel 1 for a vehicle 2, wherein the solar body panel 1 comprises a solar module 3 as proposed.

[0035] Since the solar module 3 of the solar body panel 1 is designed as proposed and thus might be manufactured by the proposed method, all explanations given with regard to the method and the solar module 3 are fully applicable.

[0036] As already described in context with the method, the solar body panel 1 may form a part of the body of the vehicle 2. As it is shown in fig. 1 , the solar body panel 1 forms the roof of the vehicle 2, but however, the solar body panel 1 may alternatively form the door or the hood of the vehicle 2 or a part of the roof, a door or a hood of the vehicle 2. Alternatively, as described earlier on, the solar body panel 1 may be attached to a part of the body of the vehicle 2 and thus, in particular, does not form a part of the body itself.

[0037] It is preferred that the solar body panel 1 comprises several solar modules 3, wherein each solar module 3 might be designed as proposed. This is also shown in fig. 1 , wherein the solar body panel 1 comprises ten solar modules 3. The solar modules 3 might be arranged in a module array.

[0038] Furthermore, it is particularly preferred that the solar body panel 1 comprises a polymer body. The polymer body is at least partially, preferably fully, formed by the polymer structure 5 of the solar module 3 or, like here, the polymer structures 5 of the solar modules 3. Thus, manufacturing of the polymer body and manufacturing of the solar module 3 or solar modules 3 may take place in one and the same manufacturing procedure.

[0039] In context with the polymer body of the solar body panel 1 , it is generally preferred that the polymer body and the polymer structure 5 of the solar module 3 or the polymer structures 5 of the solar modules 3 are designed integrally as a single piece, as it is the case in fig. 1. It is preferred, that the polymer structures 5 of the solar modules 3 composing the solar body panel 1 are molded in a single injection molding procedure. In one embodiment, the solar body panel 1 comprises a curved polymer structure 5.

[0040] As shown in fig. 1 and preferably, in assembled condition of the solar body panel 1 , namely when the solar body panel 1 is attached to the vehicle 2, the photovoltaic structure 4 of the solar module 3 or of each of the solar modules 3 is arranged on top of the polymer structures 5 of the solar module 3 or of each of the solar modules 3, at least in parts.

Claims

Claims1. Method for manufacturing a solar module (3) comprising a photovoltaic structure (4), on which a polymer structure (5) is molded, wherein the method comprises- using an injection molding machine (6) with a mold (7),- attaching an electrical connector (9), in particular comprising or being a spring conductor (10), to a photovoltaic structure (4),- placing the photovoltaic structure (4) into the mold (7) of the injection molding machine (6), wherein the mold (7) is in an open position such that the photovoltaic structure (4) can be placed within the mold (7),- performing an injection procedure for manufacturing the polymer structure (5) onto the photovoltaic structure (4), wherein during the injection procedure the mold (7) performs a closing movement and a polymer is injected into the mold (7) such that the polymer covers the photovoltaic structure (4) and the electrical connector (9) at least partly, wherein during the injection procedure the electrical connector (9) being attached to the photovoltaic structure (4) performs a compensation movement, in particular a spring movement, wherein the compensation movement is caused by the closing movement of the mold (7), wherein during the compensation movement the electrical connector (9) at least partly moves relatively to the photovoltaic structure (4).

2. Method according to claim 1 , characterized in that the injection procedure is an injection compression procedure and wherein, preferably, the closing movement comprises an initial closing phase, in which the mold (7) is moved to an initial injection position, that in the initial injection position the polymer is at least partly injected into the mold (7), and / or, that the closing movement comprises a compression closing phase, in which the mold (7) is moved to a compression injection position and the injected polymer is compressed inside the mold (7).

3. Solar module for a solar body panel (1 ) of a vehicle (2), wherein the solar module (3) comprises a photovoltaic structure (4) and a polymer structure (5), wherein the polymer structure (5) is molded onto the photovoltaic structure (4), and an electrical connector (9) for connecting the photovoltaic structure (4) toan electric component (14), such as a junction box, of the vehicle (2), wherein the electrical connector (9) extends from the photovoltaic structure (4) through the polymer structure (5), wherein the electrical connector (9) on its one end (12) concludes with the outer surface (16) of the polymer structure (5) such that an electrical junction (13) is formed.

4. Solar module according to claim 3, characterized in that the electrical connector (9) comprises or being a spring conductor (10), preferably, that the spring conductor (10) is designed at least in sections, in particular fully, as a plane spring conductor (10), and / or, that the spring conductor (10) is designed as one piece, and / or, that the spring conductor (10) is made out of bare metal, and / or, that the spring conductor (10) comprises a longitudinal section, which is double-eight-shaped, Z-shaped or 3-shaped.

5. Solar body panel for a vehicle (2), wherein the solar body panel (1 ) comprises a solar module (3) according to claim 3 or 4.

Citation Information

Patent Citations

  • Car sunroof with solar cells

    DE19813324A1

  • Photovoltaic module

    US4830038A

  • Injection molded, blow molded, and rotational molded articles that integrally incorporate a photovoltaic device, and method and system for producing such articles

    WO2022091088A1

  • Flexible solar panels incorporated within non-planar generally-rigid vehicular components

    WO2023073714A1