Vehicle body, method for producing such vehicle body, and vehicle comprising such vehicle body

Abstract

A vehicle body portion comprising at least one energy storage module arranged to at least partially form the vehicle body portion. The at least one energy storage module comprises at least one structural layer comprising a first plurality of sub-layers, at least one energy storage layer arranged on the at least one structural layer, wherein the at least one energy storage layer comprises a second plurality of sub-layers, and is configured to store first electric energy, and at least one protective layer at least partially enclosing the at least one energy storage module, wherein the at least one protective layer comprises a third plurality of sub-layers. Each of the plurality of sub-layers comprises different material compositions.

Description

[0001] Vehicle body, method for producing such vehicle body, and vehicle comprising such vehicle body

[0002] Technical field

[0003] The present invention relates to the technical field of vehicle bodies and production of vehicle bodies. In particular, the present invention relates to the technical field of vehicle bodies for hybrid electric or electric vehicles, and producing such vehicle bodies.

[0004] Background

[0005] The vehicle body of a vehicle plays a crucial role in the design, functionality, and overall endurance of the vehicle. The vehicle body is often constructed to meet various requirements within safety, aerodynamics, aesthetics, practicality, etc. Traditional vehicle bodies may consists of steel or aluminium plates augmented with various composite materials.

[0006] Furthermore, the advancement of Hybrid Electrical Vehicles (HEVs) and Electric Vehicles (EV) have been in full motion for the last decades, with a continuously increased consumer demand. A few examples of numerous advantages the HEVs and EV compared to the traditional Combustion Engine Vehicle (ICEVs) encompass improved fuel and energy efficiency, an improved driving experience due to for example silent operation and quick and responsive acceleration, as well as a decreased impact on the environment.

[0007] In regard to the energy storage for a HEV and EV, it is typically lithium-ion (Li-ion) batteries, providing high energy density, durability, and relatively low weight. The placement of a battery pack comprising a plurality of Li-ion batteries in the vehicle body differs, and depends on various factors such as size of the vehicle, design objectives, weight distribution targets, etc. Nonetheless, the Li-ion battery is not without flaws, with safety risks due to overheating of the battery as a critical weakness. Therefore, size and placement of the battery pack has to be carefully considered to ensure safety of a user of the vehicle, while simultaneously balancing weight of the battery with energy density and capacity of the battery.

[0008] Therefore, there is a need to further improve the energy efficiency for vehicles utilizing electric energy as an energy source, as well as providing a safe operating experience for a user.

[0009] Summary

[0010] It would be advantageous to at least alleviate some of the above-mentioned drawbacks. To better address one or more of these concerns a vehicle body is presented, as well as a method for producing such a vehicle body and a vehicle comprising such vehicle body. Preferred embodiments of the apparatuses and method are defined in the dependent claims.

[0011] Hence, according to a first aspect of the present invention, there is provided a vehicle body portion comprising at least one energy storage module arranged to at least partially form the vehicle body portion. The at least one energy storage module comprises at least one structural layer comprising a first plurality of sub-layers, at least one energy storage layer arranged on the at least one structural layer, wherein the at least one energy storage layer comprises a second plurality of sub-layers, and is configured to store first electric energy, and at least one protective layer at least partially enclosing the at least one energy storage module, wherein the at least one protective layer comprises a third plurality of sub-layers. Each of the pluralities of sub-layers comprises different material compositions.

[0012] According to a second aspect of the present invention, there is provided a method for producing the vehicle body portion, the method comprising providing the at least one structural layer and screen printing at least one of the at least one energy storage layer and the at least one protective layer to form the at least one energy storage module together with the at least one structural layer. The method further comprises forming the vehicle body portion by at least one of moulding, laminating, bending, and pressing a base material, wherein the base material comprises the at least one energy storage module.

[0013] According to a third aspect of the present invention, there is provided a vehicle comprising at least one vehicle body portion, wherein the vehicle is a hybrid electric vehicle or an electric vehicle.

[0014] Thus, the first, second, and third aspects of the present invention are based on the common concept or idea of providing a vehicle body portion, a method for producing the vehicle body portion, or a vehicle comprising the vehicle body portion, wherein the vehicle body portion enables an improved efficiency at least in terms of energy for a vehicle, as well as increasing the safety and operating experience for a user of the vehicle. This is achieved by a vehicle body portion comprising (an) energy storage module(s), thus enabling storage of energy in the vehicle body portion. Hence, the first, second, and third aspects share a common general inventive concept of providing a vehicle body portion comprising (an) incorporated, integrated, joined, or the like energy storage module(s).

[0015] It will be appreciated that the at least one energy storage module is arranged to at least partially form the vehicle body portion. In other words, the energy storage module(s) may be integrated, incorporated, merged, intertwined, or the like to form at least a portion of the vehicle body portion. Hence, the vehicle body portion may result in a more compact vehicle body compared to prior art where an energy storage device is often fabricated as an external unit, for positioning on or in a vehicle. Subsequently, the present invention allows for an increased interior space of a vehicle. Additionally, the energy storage module(s) provides for a more versatile and adaptable vehicle body portion in regard to need, requirements, and / or desires related to for example design.

[0016] It will be further appreciated that the weight of the energy storage module may be more evenly distributed across the vehicle body portion. This may improve the operating experience of a user of a vehicle comprising the vehicle body portion. Furthermore, the total weight of the energy storage module may be reduced compared to energy storage devices of vehicles of prior art. A reduced weight of the energy storage of a vehicle may be desirable due to an increased energy efficiency of the vehicle.

[0017] It should be noted that the present invention enables a more evenly distribution of the energy storage module. Consequently, potential energy dissipation is more evenly distributed, i.e. less concentrated to (a) specific area(s). This may be favourable as possible elevated temperature hotspots are decreased. Increased operating temperatures may be harmful for the energy storage module in e.g., reducing the energy efficiency and its longevity, as well as being a safety hazard to a user of the energy storage in terms of e.g., fire, explosion, and / or release of hazardous chemicals. Furthermore, traditional energy storage devices often require some type of heating conduction and / or cooling systems to maintain the operating temperature within a specific range to prevent extreme temperature conditions that may affect the performance, safety, and longevity of the energy storage device. These additional thermal management systems are rendered obsolete by the present invention, at least due to the fact that the energy storage may be more evenly distributed, thus reducing the risk of potential elevated temperature hotspots.

[0018] It should also be noted that the present invention allows at least one of the energy storage layer(s) and the protective layer(s) to be screen printed. This enables a versatile and adaptable method of producing the vehicle body portion, in terms of need, requirements, and / or desires. Furthermore, screen printing at least one of the energy storage layer(s) and the protective layer(s) provides for a highly precise, reproducible, and time efficient method for producing the vehicle body portion.

[0019] The energy storage module comprises at least one structural layer. By the term "structural layer" it is here meant any component, element, member, or the like that can provide a structural integrity. Furthermore, said component, element, member, or the like is suitable to have additional components, elements, members, or the like arranged upon. The structural layer may for example comprise a substrate. The energy storage module further comprises at least one energy storage layer. By "energy storage layer", it is here meant any component, element, member, or the like suitable to store electric energy. Furthermore, the energy storage module comprises at least one protective layer. By the term "protective layer" it is here meant any component, element, member, or the like that is suitable to function as a barrier, shield, obstruction, or the like to at least a portion of the energy storage module. Additionally, the vehicle body portion is formed by at least one of moulding, laminating, bending, and pressing a base material, wherein the base material comprises the at least one energy storage model. By "base material", it is here meant any material, substance, medium, element, component, mixture, or the like suitable for use in at least one of the mentioned processes of moulding, laminating, bending, and pressing to form the vehicle body portion.

[0020] According to an embodiment of the present invention, the vehicle body portion may comprise structural members, wherein at least one of the structural members may comprise the at least one energy storage module. The at least one structural layer, the at least one energy storage layer, and the at least one protective layer may be arranged along a normal, N, to a surface of the at least one structural member. In other words, the vehicle body portion may comprise one or several structural members, wherein at least one structural member may comprise the energy storage module(s). The present embodiment is advantageous in that it provides for a more versatile and adaptable vehicle body portion. For example, the structural member(s) comprising the energy storage module(s) may be intermediate arranged in relation to other structural members, along the normal, N, of the energy storage module.

[0021] The structural member(s) may further provide for an increased structural integrity of the vehicle body portion. Furthermore, the different layers may be stacked on each other along the normal, N. This enables (a) more compact energy storage module(s), which may be desirable in minimizing required occupied space by the vehicle body portion in a vehicle. Additionally, arranging the structural layer(s), the energy storage layer(s), and the protective layer(s) along the normal, N, forms a layered structure of the different layers. The present embodiment is further advantageous in that a underlying layer may profit from increased protection from an overlying layers. According to an embodiment of the present invention, the at least one energy storage module may constitute at least 50% of the vehicle body portion in regard to at least one of a surface and a volume of the vehicle body portion. In other words, the energy storage module(s) may constitute, compose, make up, account for, etc., 50% or more of the surface and / or volume of the vehicle body portion. It should be noted that said percentage may be lower, for example 20%, or higher, for example 80%. The present embodiment is advantageous in that the distribution of the energy storage module(s) is increased over the surface and / or the volume of the vehicle body portion. The increased distribution of the energy storage module(s) decreases the risk for concentrated energy dissipation, thus further decreasing the risk of thermal hot spots. Therefore, the present embodiment is favourable in that the risk of impaired longevity, energy efficiency, and / or overall performance of the energy storage module(s) is decreased.

[0022] According to an embodiment of the present invention, the at least one energy storage layer may comprise at least one of a battery and a capacitor. Hence, the energy storage layer(s) may comprise a battery, a capacitor, or a combination of them both. The present embodiment is advantageous in that batteries and capacitors enables an adaptable and scalable option for storing energy. Furthermore, the environmental impact is relatively low compared to alternative energy storage. The present embodiment is further advantageous in that is enables (a) energy storage layer(s) to comprise the combination of a battery and a capacitor. This combination is desirable in that it is allows for a versatile and flexible energy storage layer(s) regarding various needs, requirements, and / or desires. The battery ensures a relatively low but steady and continuous power delivery during a relatively long duration, whilst the capacitor enables high-power output for a relatively short duration. For example, this may be favourable when integrating the vehicle body portion in a vehicle, thus providing an adaptable and versatile vehicle in regard to requirements, needs, and / or desires on energy consumption and / or operating experience. According to an embodiment of the present invention, the battery may be a solid- state battery, and the capacitor may be a supercapacitor. Hence, the energy storage layer(s) may comprise a solid-state battery, a supercapacitor, or a combination of them both. The present embodiment is advantageous in that it comprises a solid- state battery and / or a supercapacitor, which both have various of advantages. For example, solid-state batteries provides for a more safe energy storage option, as said batteries utilize a solid electrolyte compared to traditional batteries utilize a liquid electrolyte. This reduces the risk of leakage, thermal runaway, and / or fires. Furthermore, solid-state batteries may entail a higher energy density, faster recharging, extended lifespan, and have a wider temperature range for operating compared to traditional batteries. A supercapacitor also entails for a higher energy density compared to traditional capacitors, as well as longer cycle life, and more rapid charging and discharging. Said advantages of a solid-state battery and a supercapacitor allows for (a) more efficient energy storage layer(s) at least in terms of energy. Furthermore, for a vehicle comprising the vehicle body portion, the present embodiment allows for a versatile vehicle in terms of requirements and / or desires, for example energy consumption and / or operating experience.

[0023] According to an embodiment of the present invention, the vehicle body portion may comprise an energy storage unit arranged on the vehicle body portion, configured to store second electric energy. The present embodiment is advantageous in that it increases the amount of possible energy to be stored by the vehicle portion. Hence, the adaptability and reliability of the vehicle body portion is increased. For example, the energy storage module and the energy storage unit may complement each other, for example if either is malfunctioning.

[0024] According to an embodiment of the present invention, the at least one structural layer may comprise at least one of a metal, a composite, and a foil. In other words, the structural layer(s) may comprise all, or only one, of a metal, a composite, and a foil. The present embodiment is advantageous in that it further contributes and ensures the structural integrity of structural layer(s) and / or the vehicle body portion. The present embodiment also provides for an adaptable vehicle body, as for example the structural layer(s) may comprise material(s) which may be easily accessible regarding supply and / or cost.

[0025] According to an embodiment of the present invention, the vehicle body portion may comprise at least one photovoltaic layer configured to generate electric energy, and arranged on the at least one energy storage layer. The at least one photovoltaic layer may comprise a fourth plurality of sub-layers different from each of the other pluralities of sub-layers. The present embodiment is advantageous in that it provides for a renewable and sustainable energy source for the vehicle body portion. Furthermore, the usage of (a) photovoltaic layer(s) entails a decreased negative impact on the environment compared to for example a combustion engine. The present embodiment is further favourable as the photovoltaic layer(s) requires a relatively small volume for operating. Additionally, the weight of the photovoltaic layer(s) is relatively low. A small required operating volume and / or a low weight of an energy source of a vehicle body portion may be especially desirable for a vehicle comprising the vehicle body portion. This may result in a more efficient vehicle, at least in terms of energy consumption.

[0026] According to an embodiment of the present invention, the at least one photovoltaic layer may be electrically connected to the at least one energy storage layer. Hence, the energy storage layer(s) may store generated electric energy from the photovoltaic layer(s). The present embodiment is advantageous in that the generated energy by the photovoltaic layer(s) may be stored in the energy storage layer(s) to be consumed at a subsequent moment. The present embodiment is further advantageous in that the energy storage layer(s) may be repeatably recharged by the photovoltaic layer(s), if the energy storage layer(s) is (are) exhausted. This may be especially favourable in the example of a vehicle comprising the vehicle body portion. Said example provides for a vehicle with flexible and self- reliant energy supply.

[0027] According to an embodiment of the present invention, the at least one protective layer may comprise at least one of a coating, a paint, and a foil. Thus, the protective layer(s) may comprise all, or only one, of a coating, a paint, and a foil. The present embodiment is advantageous in that it provides for (a) thinner (a) protective layer(s). Furthermore, the weight of the protective layer(s) may be reduced. Thus, the present embodiment is desirable as it provides for a more compact and / or less heavier vehicle body portion.

[0028] According to an embodiment of the present invention, the at least one protective layer may be at least partially transparent. Thus, the protective layer(s) may be fully transparent, or partially transparent, i.e., translucent. In other words, incident light to the protective layer(s) would at least partially pass through the protective layers(s). The present embodiment is advantageous in that it allows potential incident light to pass through the protective layer(s). This is especially advantageous when the energy storage module comprises at least one photovoltaic layer, allowing an optimized of incident light to reach the photovoltaic layer(s). Furthermore, the present embodiment is favourable as maintenance of the energy storage module may be facilitated due to the fact the that protective layer(s) may be as least partially transparent.

[0029] According to an embodiment of the present invention, the at least one energy storage module may be peripherally arranged to at least partially form the vehicle body portion. In other words, the peripherally arranged energy storage module(s) form at least a portion of the vehicle body portion. Hence, the energy storage module(s) may be arranged at the outer edge, boundary, periphery, or the like, of the vehicle body portion, collectively creating at least a portion of the shape, outline, or the like of the vehicle body portion. Thus, the energy storage module(s) may at least partially face the surrounding environment of the vehicle body portion. The present embodiment is advantageous in that the access to the energy storage module(s) from the surrounding environment of the vehicle body portion may be improved. Hence, the maintenance of the energy storage module(s) may be facilitated. Furthermore, the present embodiment may allow potential incident light to reach the energy storage module(s) to a greater extent. This is especially advantageous according to an example where the energy storage module(s) comprises at least one photovoltaic layer. According to an embodiment of the present invention, at least one of the at least one energy storage layer, the at least one photovoltaic layer, and the at least one protective layer may be screen printed. Thus, all, or only one, of the energy storage layer(s), the photovoltaic layer(s), and the protective layer(s) may be screen printed. This entails all, or only one, of corresponding plurality of sub-layers of the energy storage layer(s), the photovoltaic layer(s), and the protective layer(s) to be screen- printed. The present embodiment is advantageous in that it provides for a versatile and dependable vehicle body portion in terms of need, requirements, and / or desires. For example, as at least one of the energy storage layer(s), the photovoltaic layer(s), and the protective layer(s) is screen printed, the present embodiment allows for a vehicle body portion being more compact and / or with a reduced weight. Furthermore, the embodiment enables the different layers to be highly precise designed in a time efficient manner. Additionally, the embodiment enables reproducibility and uniformity of the same item to a higher extent, for example a first and a second layer of the energy storage layer.

[0030] According to an embodiment of the present invention, the at least one energy storage module may be at least partially flexible. Thus, all, or only a portion, of the energy storage module(s) may be flexible. The present embodiment is advantageous in that it provides for a more adaptable energy storage module(s), and therefore also a more adaptable vehicle body portion, in regard to e.g., required and / or desired design properties. According to an example, the vehicle body portion has a curved shape. The present embodiment would enable (a) energy storage module(s) to be arranged to at least partially form the vehicle body portion along the curvature of the vehicle body portion. This may be further favourable as it allows for example a curved surface of the vehicle body portion to be formed by a single, or a relatively few, energy storage module(s). Thus, the weight of the vehicle body portion may be decreased, while also meeting the requirements, needs, and / or desires of the design of the vehicle body portion. The present embodiment may be especially advantageous for a vehicle comprising the vehicle body portion. A vehicle often comprises curved surfaces which may come in conflict with the structure and / or function of for example the vehicle body and its components. According to an embodiment of the present invention, the vehicle body portion may comprise at least two energy storage modules. At least one of the at least one energy storage layer and the at least one photovoltaic layer of each of the at least two energy storage modules may be electrically connected to at least one of the at least one energy storage layer and the at least one photovoltaic layer, respectively, of another energy storage module of the at least two energy storage modules. The present embodiment is advantageous in that a plurality of energy storage modules may be connected via the corresponding energy storage layers and / or photovoltaic layers. In other words, the vehicle body may comprise one or several composite energy storage module. This may desirable as it may increase the energy efficiency of the energy storage module(s). The present embodiment provides for a further adaptive and versatile vehicle body portion in regard to the production, handling, and / or transportation of the vehicle body portion. For example, the plurality of energy storage modules may be produced, e.g., at least partially by screen-printing, handled and transported individually. Thereafter, the plurality of energy storage modules may be arranged as a combined energy storage module, such as a composite, to at least partially form a vehicle body portion.

[0031] According to an embodiment of the present invention, the energy storage module may comprise at least one photovoltaic layer, wherein the step of screen printing may further comprise screen printing the at least one photovoltaic layer on the at least one energy storage layer to further form the at least one energy storage module. The present embodiment is advantageous in that the photovoltaic layer(s) of the energy storage module(s) may be produced by screen printing. Screen printing has several advantages, such as being highly reproducible and precise, and time efficient. Furthermore, the weight and / or the thickness of the photovoltaic layer(s), and therefore the vehicle body portion, may be reduced according to the embodiment. A more compact and / or less heavier vehicle body portion is especially favourable in regard to a vehicle. A vehicle comprising the present embodiment may entail a vehicle with an improved energy efficiency, and / or a more flexible design. In addition, the overall driving experience of an operator of the vehicle may be enhanced at least in terms of available interior space of the vehicle. Brief description of the drawings

[0032] This and other aspects of the present invention will now be described in more detail, with reference to the appended drawings showing embodiment(s) of the invention.

[0033] Fig. 1 is a cross-sectional view of a vehicle body portion according to an exemplifying embodiment of the present invention.

[0034] Fig. 2 is a cross-sectional view of a vehicle body portion according to an exemplifying embodiment of the present invention.

[0035] Fig. 3 is a cross-sectional view of a vehicle body portion according to an exemplifying embodiment of the present invention.

[0036] Fig. 4 is a schematical view of a method for producing a vehicle body portion according to an exemplifying embodiment of the present invention.

[0037] Fig. 5 is a cross-sectional view of a vehicle body portion with selected portions of the vehicle body portion visible according to an exemplifying embodiment of the present invention.

[0038] Fig. 6 is a perspective view of a vehicle comprising a vehicle body portion with selected portions of the vehicle body portion visible according to an exemplifying embodiment of the present invention.

[0039] Detailed description

[0040] The present invention will now be described more fully hereinafter with reference to the accompanying figures, in which currently preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided for thoroughness and completeness, and fully convey the scope of the invention to the skilled person. Fig. 1 is a cross-sectional view of a vehicle body portion 100 according to an exemplifying embodiment of the present invention.

[0041] The vehicle body portion 100 comprises at least one energy storage module 110 arranged to at least partially form the vehicle body portion 100. In other words, the energy storage module(s) 110 is (are) at least partially integrated, incorporated, joined, or the like in the vehicle body portion 100. Thus, the energy storage module(s) 110 forms a substantial portion of the structure of the vehicle body portion 100, rather than merely being affixed to an existing body. Thus, the energy storage module(s) 110 contributes to the overall stability of the vehicle body portion 100. The energy storage module 110 may form the vehicle body portion 100 as a whole, or only partially. It should be noted that a vehicle body may encompass a frame and / or a chassis of a vehicle. Thus, the vehicle body portion 100 may refer to various portions of a vehicle body. For example, the vehicle body portion 100 may be a portion of a frame, a chassis, and / or the overall body of a vehicle.

[0042] The at least one energy storage module 110 comprises at least one structural layer 120 comprising a first plurality of sub-layers 125. In other words, the structural layer(s) 120 provide a structural integrity to the energy storage module(s) 110. For example, the structural layer(s) 120 may comprise a substrate which is suitable to arrange additional components, elements, members, or the like upon.

[0043] The at least one energy storage module 110 further comprises at least one energy storage layer 130 arranged on the at least one structural layer 120, wherein the at least one energy storage layer 130 comprises a second plurality of sub-layers 135, and is configured to store first electric energy. The energy storage layer(s) 130 may comprise any type of energy storage means enabling storing first electric energy. For example, the energy storage layer(s) 130 may comprise a battery and / or a capacitor. According to an example, the energy storage layer(s) 130 comprises two electrode layers separated by a separator layer. The separator layer comprises an electrolyte layer and an encapsulation layer on either side facing the two electrode layers, respectively. The encapsulation layers form an electric insulation layer and may for example comprise a plastic. To promote efficiency in terms of production time and / or material usage, if two energy storage layers 130 are arranged adjacent to each other such that encapsulation layers of corresponding energy storage layers 130 are facing each other, it is feasible to design one of the energy storage layers 130 without said adjacent encapsulation layer, whilst achieving an electric insulation layer for the two energy storage layers 130. For example, encapsulation layers may be 20 pm to 250 pm thick.

[0044] The electrode layers of the energy storage layer(s) 130 may comprise carbon in various forms, such as activated carbon, activated carbon fibre, carbide-derived carbon, carbon aerogel, graphite, graphene, and / or carbon nanotubes. For example, electrode layers may range from 3 pm to 250 pm in thickness. Furthermore, the at least one electrode layer may comprise transition metal oxides such as ruthenium, iridium, iron, and / or manganese oxides, or electrically conductive polymers such as polypyrrole (PPy), polyaniline (PANI), pentacene, and / or polythiophene. The separator layer of the energy storage layer(s) 130 may comprise a porous plastic. Additionally, the separator layer may be within the range of 0.5 pm to 250 pm thick. Furthermore, the electrolyte may comprise an aqueous electrolyte solution, an organic electrolyte solution, an ionic liquid, a superconcentrated electrolyte, and / or an electrically conductive polymer.

[0045] The at least one energy storage module 110 further comprises at least one protective layer 140 at least partially enclosing the at least one energy storage module 110, wherein the at least one protective layer 140 comprises a third plurality of sub-layers 145. Hence, the protective layer(s) 140 may enclose the energy storage module(s) 110 as a whole, or only partially.

[0046] Furthermore, each of the plurality of sub-layers comprises different material compositions. Hence, the first plurality of sub-layers 125 of the structural layer(s) 120, the second plurality of sub-layers 135 of the energy storage layer(s) 130, and the third plurality of sub-layers 145 of the protective layer(s) 140 differ in their material composition. The structural layer(s) 120, the energy storage layer(s) 130, and the protective layer(s) 140 extends along an axis, A, (not shown) perpendicular to the normal, N. According to an example, the at least one energy storage module 110 is configured to provide electric energy to a motor. Furthermore, the motor may be arranged within a vehicle comprising the vehicle body portion 100 comprising the energy storage module(s) 110. Therefore, the energy storage module(s) 110 may further comprise a first connector configured to electrically connect the energy storage layer(s) 130 to an external device, to provide electrical energy to the device.

[0047] Fig. 2 is a cross-sectional view of a vehicle body portion 100 according to an exemplifying embodiment of the present invention. It should be noted that the vehicle body portion 100 shown in Fig. 2 has several features in common with the vehicle body portion 100 shown in Fig. 1, and it is hereby referred to Fig. 1 and the associated text for an increased understanding of some of the features and / or functions of the vehicle body portion 100 in Fig. 2.

[0048] The vehicle body portion 100 according to Fig. 2 comprises structural members 150, wherein at least one of the structural members 150 comprises the at least one energy storage module 110. Thus, all, or only one, of the structural members 150 may comprise one or several energy storage modules 110. For conciseness and clearness, the vehicle body portion 100 of Fig. 2 comprises two structural members 150, wherein one structural member 150 comprises one energy storage module 110.

[0049] Furthermore, the at least one structural layer 120, the at least one energy storage layer 130, and the at least one protective layer 140 are arranged along a normal, N, to a surface of the at least one structural member 150. Hence, as shown in Fig. 2, said layers 120, 130, 140 are arranged in a stacked manner, wherein the overlying layer aligns with the underlying layer. It should be noted that other arrangements of the layers 120, 130, 140 depicted herein are feasible.

[0050] The at least one structural layer 120 comprises at least one of a metal, a composite, and a foil. Hence, the first plurality of sub-layers 125 may comprise a metal, a composite, and / or a foil. The composite may for example comprise glass fibre and / or carbon fibre. Additionally, the structural layer(s) 120 may comprise a plastic, a polycarbonate, and / or a glass. The at least one protective layer 140 may comprise at least one of a coating, a paint, and a foil. Hence, the third plurality of sub-layers 145 may comprise a coating, a paint, and / or a foil.

[0051] According to Fig. 2, the at least one energy storage module 110 constitutes at least 50% of the vehicle body portion 100 in regard to at least one of a surface and a volume of the vehicle body portion 100. In other words, the energy storage module(s) 110 coverage percentage in regard to the surface and / or the volume of the vehicle body portion 100 is at least 50%. It should be noted that said coverage percentage may be lower, for example 20%, or higher, for example 80%.

[0052] The at least one energy storage layer 130 of the energy storage module(s) 110 may comprise at least one of a battery and a capacitor. Hence, the second plurality 135 of the energy storage layer(s) 130 may comprise a battery and / or a capacitor. According to Fig. 2, the energy storage layer(s) 130 comprises both a battery and a capacitor. For example, the battery may be a solid-state battery, and the capacitor may be a supercapacitor.

[0053] The vehicle body portion 100 of Fig. 2 further comprises an energy storage unit 160 arranged on the vehicle body portion 100, configured to store second electric energy. The energy storage unit 160 may be arranged anywhere on the vehicle body portion 100. Whereas the energy storage module(s) 110 at least partially forms the vehicle body portion 100, the energy storage unit 160 is arranged on the vehicle body portion 100 and does not necessary contribute to the structural integrity of the vehicle body portion 100. According to an example, the vehicle body portion 100 at least partially encloses the energy storage unit 160. According to yet another example, a vehicle body comprises the vehicle body portion 100, wherein the energy storage unit 160 is fully enclosed by the vehicle body. In other words, the energy storage unit 160 is arranged inside, internally, interior, or the like of the vehicle body comprising the vehicle body portion 100.

[0054] The energy storage unit 160 may be electrically connected to the energy storage module(s) 110. More specifically, the energy storage unit 160 may be electrically connected to the energy storage layer(s) 130. Similar to an exemplifying embodiment described herein of the energy storage module(s) 110, the at least one energy storage unit 160 may be configured to provide electric energy to a motor. Furthermore, the motor may be arranged within a vehicle comprising the vehicle body portion 100 comprising the energy storage unit 160. Therefore, the energy storage module(s) 110 may comprise a second connector configured to electrically connect the energy storage layer(s) 130 to an external device, to provide electrical energy to the device. The energy storage unit 160 and the energy storage module(s) 110 may be configured to provide electric energy to a same motor. According to an example, providing the first and second electric energy to said same motor may be performed according to a control scheme. For example, extracting energy from the energy storage module(s) 110 may be prioritized over extracting energy from the energy storage unit 160.

[0055] Fig. 3 is a cross-sectional view of a vehicle body portion 100 according to an exemplifying embodiment of the present invention. It should be noted that the vehicle body portion 100 shown in Fig. 3 has several features in common with the vehicle body portion 100 shown in Figs. 1 and 2, and it is hereby referred to Figs. 1 and 2 along with the associated text for an increased understanding of some of the features and / or functions of the vehicle body portion 100 in Fig. 3.

[0056] The vehicle body portion 100 according to Fig. 3 comprises at least one photovoltaic layer 170 configured to generate electric energy. The at least one photovoltaic layer 170 is arranged on the at least one energy storage layer 130. The at least one photovoltaic layer 170 comprises a fourth plurality of sub-layers 175 different from each of the other pluralities of sub-layers 125, 135, 145. The at least one photovoltaic layer 170 is electrically connected to the at least one electric storage module 110. More specifically, the at least one photovoltaic layer 170 is electrically connected to the at least one energy storage layer 130. This enables transmittance of electric energy from the at least one photovoltaic layer 170 to the at least one energy storage layer 130. Hence, the photovoltaic layer(s) 170 may generate electric energy which is stored in the energy storage layer(s) 130. The photovoltaic layer(s) 170 may be directly connected to the energy storage layer(s) 130, or indirectly. In the example of an indirect connection, the photovoltaic layer(s) 170 and the energy storage layer(s) 130 may be connected via a junction box. The example enables the photovoltaic layer(s) 170 and the energy storage layer(s) 130 to at least partially be separated.

[0057] The at least one energy storage module 110 is according to Fig. 3 at least partially flexible. In other words, the energy storage module(s) 110 may be fully flexible, or only a portion of it. Furthermore, all, or only some, of the structural layer(s) 120, the energy storage layer(s) 130, the photovoltaic layer(s) 170, and the protective layer(s) 140 may be as least partially flexible. This facilitates for the energy storage module(s) 110 to at least partially form the vehicle body portion 100.

[0058] The photovoltaic layer(s) 170 may comprise a thin-film solar cell. The thin-film solar cell may comprise photoactive materials such as amorphous silicon (a-Si :H), microcrystalline silicon (mc-Si:H), gallium arsenide (GaAs), cadmium telluride (CdTe), and / or copper-indium-(gallium)-sulfur-selenium compounds.

[0059] According to an example, the sub-layers 175 of the photovoltaic layer(s) 170 may comprise at least one translucent front electrode layer, at least one support structure layer, at least one photoactive layer comprising the photoactive material, at least one transport layer, at least one back electrode layer, and at least one encapsulation layer at least partially enclosing the photovoltaic layer 170. The support structure layer may contribute to mechanical stability to the photovoltaic layer(s) 170, and / or to stabilize the photoactive material. The support structure layer may comprise various types of glass, polymethyl methacrylate (PMMA), metal foils, and / or plastic foils. The thickness of the support structure layer(s) may be within a range of 100 nm to 5 pm. The photoactive layer is preferably within the range of 50 nm to 5 pm in thickness. The transport layer(s) is favourable in maintaining charge separation. Furthermore, the transport layer(s) may comprise negative and positive arrangements of organic and / or inorganic materials, thus aiding in electron transport. The thickness of the transport layer may be between 50 nm and 5 pm. The back electrode layer is preferably between 100 nm and 15 pm thick, whereas the front electrode layer(s) may for example range between 100 nm and 5 pm in thickness. The sub-layers 175 may be stacked on top of each other, along the normal, N. According to yet another example, the support structure layer(s) and the transport layer(s) are omitted, resulting in a thinner photovoltaic layer(s) 170.

[0060] The encapsulation layer of the sub-layers 175 may be designed as an electrical insulation layer. Furthermore, the encapsulation layer may comprise a plastic. The encapsulation layer adjacent to the front electrode may be between 20 pm and 250 pm thick, whereas the encapsulation layer adjacent to the back electrode may have a thickness ranging from 500 nm to 250 pm. To promote efficiency in terms of production time and / or material usage, if two photovoltaic layers 170 are arranged adjacent to each such that the encapsulation layers of corresponding photovoltaic layer 170 are facing each other, it is feasible to design one of the photovoltaic layer 170 without said adjacent encapsulation layer, whilst achieving an electric insulation layer for the two photovoltaic layers 170.

[0061] The at least one protective layer 140 of the at least one energy storage module 110 may be at least partially transparent. Thus, the protective layer(s) 140 may be fully transparent, or partially transparent, i.e., translucent. In other words, incident light to the protective layer(s) 140 would at least partially pass through the protective layers(s) 140. This is especially advantageous in regard to the photovoltaic layer(s) 170, to increase the amount of incident light reaching the photovoltaic layer(s) 170.

[0062] According to an example, the at least one energy storage module 110 is peripherally arranged to at least partially form the vehicle body portion 100. Thus, the energy storage module(s) 110 is facing the surrounding environment of the vehicle body portion 100. This is especially advantageous in regard to the photovoltaic layer(s) 170, to provide incident light to the photovoltaic layer(s) 170 to a greater extent.

[0063] According to Fig. 3, at least one of the at least one energy storage layer 130, the at least one photovoltaic layer 170, and the at least one protective layer 140 is screen printed. Thus, all of the energy storage layer(s) 130, the photovoltaic layer(s) 170, and the protective layer(s) 140 may be screen printed, or only some. According to an example, the layers 130, 170, 140 are screen printed on the structural layer(s) 120. According to yet another example, the energy storage layer(s) 130 and the photovoltaic layer(s) 170 are screen printed on the protective layer(s) 140. The materials for producing the energy storage layer(s) 130, the photovoltaic layer(s) 170, and the protective layer(s) 140 may be provided as pastes, to facilitate the screen printing process.

[0064] The vehicle body portion 100 comprises at least two energy storage modules 110. According to Fig. 3, the vehicle body portion 100 comprises exactly two energy storage modules 110. At least one of the at least one energy storage layer 130 and the at least one photovoltaic layer 170 of each of the at least two energy storage modules 110 is electrically connected to at least one of the at least one energy storage layer 130 and the at least one photovoltaic layer 170, respectively, of another energy storage module 110 of the at least two energy storage modules 110. According to an example, the energy storage modules 110 does not comprise photovoltaic layers 170. Thus, comparing the example to Fig. 3, it is only the corresponding energy storage layers 130 of the two energy storage modules 110 that would be electrically connected. Thus, the two energy storage modules 110 according to Fig. 3 constitute a composite energy storage module. This may be favourable in the case where production process of the energy storage module(s) 110 imposes constraints. Such constraints may be printing constraints of the various layers of the energy storage module(s) 110, for example with maximum dimensions of 50 cm by 50 cm or 120 cm by 100 cm. Thus, establishing connections between multiple energy storage modules 110 to create a composite energy storage module may be desirable.

[0065] One aspect of the invention is to seamlessly integrate the energy storage module(s) 110 into the vehicle body portion 100. In traditional fully electric or hybrid vehicles, the energy storage devices such as batteries are often engineered as an independent unit within the vehicle. Furthermore, the integration of potential solar cells is considered as a separate layer added to the vehicle's exterior. On the contrast, the present invention provides a vehicle body portion 100 comprising energy storage module(s) 110 arranged to at least partially form the vehicle body portion 100 and contributing to the structural integrity of the vehicle body portion 100.

[0066] Fig. 4 is a schematical view of a method 300 for producing a vehicle body portion according to an exemplifying embodiment of the present invention. It should be noted that the vehicle body portion of the method 300 shown in Fig. 4 has several features in common with the vehicle body portion shown in Figs. 1 to 3, and it is hereby referred to Figs. 1 to 3 along with the associated text for an increased understanding of some of the features and / or functions of the vehicle body portion in Fig. 4.

[0067] The method 300 for producing the vehicle body according to Fig. 4 comprises providing 310 the at least one structural layer and screen printing 320 at least one of the at least one energy storage layer and the at least one protective layer to form the at least one energy storage module together with the at least one structural layer. According to an example, the energy storage layer(s) and / or the protective layer(s) may be screen printed 320 on the structural layer(s). According to yet another example, the energy storage layer(s) is screen printed 320 on the structural layer(s), and the protective layer(s) is screen printed 320 such that it at least partially encloses the energy storage module(s). For example, the energy storage layer(s) and / or the protective layer(s) may be screen printed 320 using a paste.

[0068] The method 300 further comprises forming 330 the vehicle body portion by at least one of moulding, laminating, bending, and pressing a base material, wherein the base material comprises the at least one energy storage module. The base material may be any type of material suitable to use for at least one of moulding, laminating, bending, and pressing. Thus, the energy storage module(s) at least partially forms the vehicle body portion.

[0069] The energy storage module according to Fig. 4 comprises at least one photovoltaic layer, wherein the step of screen printing 320 further comprises screen printing 320 the at least one photovoltaic layer on the at least one energy storage layer to further form the at least one energy storage module. According to an example, the photovoltaic layer(s) is screen printed 320 on the energy storage module(s).

[0070] Fig. 5 is a cross-sectional view of a vehicle body portion 100 with selected portions of the vehicle body portion 100 visible according to an exemplifying embodiment of the present invention. It should be noted that the vehicle body portion 100 shown in Fig. 5 has several features in common with the vehicle body portion 100 shown in Figs. 1 to 3, and it is hereby referred to Figs. 1 to 3 along with the associated text for an increased understanding of some of the features and / or functions of the vehicle body portion 100 in Fig. 5.

[0071] The vehicle body portion 100 according to Fig. 5 may constitute several vehicle body portions 100, if desirable. This may facilitate the production of the vehicle body portions 100, as well as the managing and transporting. The energy storage modules 110 are arranged along a normal Ni and N2, respectively, to the vehicle body portion 100. It should be noted that the energy storage module(s) 110 may be arranged anywhere on a vehicle body, for example in a frame, a chassis, a roof, and / or a hood.

[0072] Fig. 6 is a perspective view of a vehicle 400 comprising a vehicle body portion 100 with selected portions of the vehicle body portion 100 visible according to an exemplifying embodiment of the present invention. It should be noted that the vehicle body portion 100 of the vehicle 400 shown in Fig. 6 has several features in common with the vehicle body portion 100 shown in Figs. 1 to 3 and 5, and it is hereby referred to Figs. 1 to 3 and 5 along with the associated text for an increased understanding of some of the features and / or functions of the vehicle body portion 100 in Fig. 6.

[0073] The vehicle 400 according to Fig. 6 comprises a plurality of vehicle body portions 100. The vehicle 400 may be a hybrid electric vehicle or an electric vehicle. The vehicle 400 according to Fig. 5 is an automobile. Nonetheless, the vehicle 400 may be a various of vehicle types, such as motorcycles, quads, trucks, bicycles, aircrafts, boats, ships, spacecrafts, satellites etc. The person skilled in the art realizes that the present invention by no means is limited to the preferred embodiments described above. On the contrary, many modifications and variations are possible within the scope of the appended claims. For example, the vehicle body portion 100, the energy storage module(s) 110, the structural members 150, etc., may have different shapes, dimensions and / or sizes than those depicted / described. Furthermore, the order of the at least one structural layer 120, the at least one energy storage layer 130, the at least one photovoltaic layer 170, and the at least one protective layer 140 may be different from the order described herein.

Claims

CLAIMS1. A vehicle body portion (100) comprising at least one energy storage module (110) arranged to at least partially form the vehicle body portion, wherein the at least one energy storage module comprises at least one structural layer (120) comprising a first plurality of sub-layers (125), at least one energy storage layer (130) arranged on the at least one structural layer, wherein the at least one energy storage layer comprises a second plurality of sub-layers (135), and is configured to store first electric energy, and at least one protective layer (140) at least partially enclosing the at least one energy storage module, wherein the at least one protective layer comprises a third plurality of sub-layers (145), wherein each of the plurality of sub-layers comprises different material compositions.

2. The vehicle body portion according to claim 1, comprising structural members (150), wherein at least one of the structural members comprises the at least one energy storage module, wherein the at least one structural layer, the at least one energy storage layer, and the at least one protective layer are arranged along a normal, N, to a surface of the at least one structural member.

3. The vehicle body portion according to claim 1 or 2, wherein the at least one energy storage module constitutes at least 50% of the vehicle body portion in regard to at least one of a surface and a volume of the vehicle body portion.

4. The vehicle body portion according to any one of the preceding claims, wherein the at least one energy storage layer comprises at least one of a battery and a capacitor.

5. The vehicle body portion according to claim 4, wherein the battery is a solid- state battery, and the capacitor is a supercapacitor.

6. The vehicle body portion according to any one of the preceding claims, comprising an energy storage unit (160) arranged on the vehicle body portion, configured to store second electric energy.

7. The vehicle body portion according to any one of the preceding claims, wherein the at least one structural layer comprises at least one of a metal, a composite, and a foil.

8. The vehicle body portion according to any one of the preceding claims, comprising at least one photovoltaic layer (170) configured to generate electric energy, and arranged on the at least one energy storage layer, wherein the at least one photovoltaic layer comprises a fourth plurality of sub-layers (175) different from each of the other pluralities of sub-layers.

9. The vehicle body portion according to claim 8, wherein the at least one photovoltaic layer is electrically connected to the at least one energy storage layer.

10. The vehicle body portion according to any one of the preceding claims, wherein the at least one protective layer comprises at least one of a coating, a paint, and a foil.

11. The vehicle body portion according to any one of the preceding claims, wherein the at least one protective layer is at least partially transparent.

12. The vehicle body portion according to any one of the preceding claims, wherein the at least one energy storage module is peripherally arranged to at least partially form the vehicle body portion.

13. The vehicle body portion according to any one of the preceding claims, wherein at least one of the at least one energy storage layer, the at least one photovoltaic layer, and the at least one protective layer is screen printed.

14. The vehicle body portion according to any one of the preceding claims, wherein the at least one energy storage module is at least partially flexible.

15. The vehicle portion according to any one of the preceding claims, comprising at least two energy storage modules, wherein at least one of the at least one energy storage layer, and the at least one photovoltaic layer of each of the at least two energy storage modules is electrically connected to at least one of the at least one energy storage layer and the at least one photovoltaic layer, respectively, of another energy storage module of the at least two energy storage modules.

16. A method (300) for producing the vehicle body portion according to any one of the preceding claims, the method comprising providing (310) the at least one structural layer, screen printing (320) at least one of the at least one energy storage layer and the at least one protective layer to form the at least one energy storage module together with the at least one structural layer, forming (330) the vehicle body portion by at least one of moulding, laminating, bending, and pressing a base material, wherein the base material comprises the at least one energy storage module.

17. The method according to claim 16, wherein the energy storage module comprises at least one photovoltaic layer, wherein the step of screen printing further comprises screen printing the at least one photovoltaic layer on the at least one energy storage layer to further form the at least one energy storage module.

18. A vehicle (400) comprising at least one vehicle body portion according to any one of claims 1 to 15, wherein the vehicle is a hybrid electric vehicle or an electric vehicle.

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