Vehicle Hood Photovoltaic Module Molding Integration

The patent merges the photovoltaic module with the vehicle body by integrating it into the molding process of the body component itself. The photovoltaic module is embedded directly into the molded part during manufacturing, eliminating the need for separate brackets or mounting structures. This integration approach removes the additional weight and complexity of mounting hardware while maintaining power generation functionality.

The vehicle body component serves multiple functions: it provides structural support, maintains aesthetic appearance, and simultaneously houses the photovoltaic power generation system. By making the body component itself the integration substrate, the design achieves multi-functionality without requiring additional specialized structures for solar panel mounting.

The molding process integration approach is universally applicable to various vehicle body components including hoods, doors, fenders, and roofs. By embedding the photovoltaic module directly into the molding process of different body parts, the system can be deployed across the entire vehicle body surface area, not limited to just the roof as with glass encapsulation methods.

The patent changes the material state and processing parameters by using thermoplastic materials that can be molded at elevated temperatures. This allows the photovoltaic module to be integrated into complex three-dimensional body shapes that would be difficult or impossible to achieve with rigid double-layer glass structures, enabling application on various vehicle surfaces.

The photovoltaic module undergoes pre-heating before being placed in the mold cavity. This preliminary thermal treatment brings the module to a temperature closer to the molding temperature, reducing the thermal shock and temperature differential during the molding process. This helps prevent deformation by allowing more gradual and uniform heating during encapsulation.

The patent introduces a buffering material between the photovoltaic module and the mold cavity wall. This intermediary layer acts as a thermal and mechanical buffer, distributing the heat and pressure more evenly during the molding process and preventing direct contact that could cause localized deformation or damage to the photovoltaic cells.