Architectural panels with organic photovoltaic interlayers and methods of forming the same

• US 8,418,418 B2
• Filed: 04/09/2010
• Issued: 04/16/2013
• Est. Priority Date: 04/29/2009
• Status: Expired due to Fees

• Current Assignee: 3Form LLC (Armstrong World Industries Incorporated)
• Original Assignee: 3Form (Hunter Douglas N.V.)
• Inventors: Willham, John E. C., Brewster, M. Hoyt
• Primary Examiner(s): Chapman, Jeanette E
• Assistant Examiner(s): BUCKLE JR, JAMES J
• Application Number:
  US13/263,978
• Publication Number:
  US 20120117896A1
• Time in Patent Office: 1,103 Days
• Field of Search: 521/733, 136/243, 136/244, 136/245, 136/246, 136/247, 136/248, 136/249, 136/250, 136/251, 126/621, 126/622, 428/143, 428/913
• US Class Current: 52/173.3
• CPC Class Codes: B32B 2457/12 Photovoltaic modules
• CPC Class Codes: H01L 31/042 PV modules or arrays of single PV cells supporting structures for PV modules H02S20/00
• CPC Class Codes: H01L 31/048 Encapsulation of modules
• CPC Class Codes: H10K 39/10 Organic photovoltaic [PV] modules; Arrays of single organic PV cells
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product

Abstract

A method of making a photovoltaic panel includes previously preparing one or more pre-formed substrates with a first temperature and pressure to be non-planar, textured, embossed, colored, or combinations thereof. A manufacturer can then prepare a laminate assembly comprising one or more organic photovoltaic components one or more pre-formed substrates, and a barrier layer with one or more thermally-activated thermoplastic tie layers there between. The manufacturer can then finish the photovoltaic panel lamination by subjecting the assembly to a second set of temperatures and pressures sufficient to activate and bond the pre-formed substrate, barrier layer, and photovoltaic components without significantly softening the pre-formed substrates or otherwise degrading/damaging the organic photovoltaic components. A non-planar panel made by this method can be used in both exterior and interior decorative and/or structural applications where electrical generation is desired.

Claims

1. An organic photovoltaic panel having sufficient rigidity for use as a building component, the photovoltaic panel comprising:

a rigid, pre-formed substrate comprising an upper surface and a lower surface, the rigid pre-formed substrate having sufficient rigidity and strength for use as a building component;

one or more flexible organic photovoltaic components comprising one or more organic photovoltaic cells adhered within an encapsulation film, wherein the one or more organic photovoltaic components are fused via the encapsulation film to the upper surface of the pre-formed substrate; and

an at least partially translucent barrier layer fused to at least the one or more organic photovoltaic components;

wherein;

the one or more organic photovoltaic components are preserved from degradation by the pre-formed substrate and at least partially translucent barrier layer; and

the organic photovoltaic panel has a lamination strength of at least about 2 ft.-lbs of force.

2. The panel as recited in claim 1, wherein the pre-formed substrate comprises a non-planar configuration.

3. The panel as recited in claim 1, wherein the upper surface of the pre-formed substrate is textured.

4. The panel as recited in claim 1, wherein the one or more organic photovoltaic components are translucent.

5. The panel as recited in claim 1, further comprising spacing between the one or more organic photovoltaic components configured to allow light to pass through the organic photovoltaic panel.

6. The panel as recited in claim 1, wherein the at least partially translucent barrier layer comprises a second, rigid pre-formed substrate.

7. The panel as recited in claim 1, wherein the one or more organic photovoltaic components are at least a first distance from each edge of the upper surface of the pre-formed substrate.

8. The panel as recited in claim 7, wherein the at least partially translucent barrier layer is positioned at least a second distance from each edge of upper surface of the pre-formed substrate, wherein the first distance is greater than the second distance.

19. The panel as recited in claim 1, further comprising at least one tie layer located between the at least one encapsulation layer of the one or more organic photovoltaic components and the pre-formed substrate, and the tie layer fuses the at least one encapsulation layer of the one or more organic photovoltaic components to the pre-formed substrate.

20. The panel as recited in claim 1, wherein the barrier layer is further fused directly to the rigid pre-formed substrate, such that the barrier layer is fused directly to each of the pre-formed substrate and the one or more organic photovoltaic components.

9. A structure configured to provide cover from outside elements and generate power from one or more light sources using one or more organic photovoltaic elements, comprising:

a frame; and

one or more translucent, photovoltaic, power-generating architectural panels mounted to the frame, wherein the one or more architectural panels include;

one or more translucent, flexible organic photovoltaic components comprising an organic photovoltaic material adhered within an encapsulation film;

a rigid, pre-formed translucent substrate fused to the encapsulation film of the one or more organic photovoltaic components, wherein the encapsulation film prevents the organic photovoltaic components from direct contact with the rigid, pre-formed translucent substrate; and

a barrier layer fused to one or more of the pre-formed substrate and the encapsulation film of the one or more organic photovoltaic components;

wherein the one or more architectural panels are sufficiently strong, and rigid or inflexible, and thereby suited for use as a building material.

10. The building structure as recited in claim 9, wherein at least one of the one or more architectural panels has a non-planar shape.

11. The building structure as recited in claim 9, wherein the at least one of the one or more architectural panels has a non-planar configuration.

12. The building structure as recited in claim 9, wherein the one or more organic photovoltaic components and pre-formed substrate are fused together as a rigid and inflexible photovoltaic panel for use as a building material or component.

13. The building structure as recited in claim 9, wherein at least a portion of the organic photovoltaic component adhered to the rigid, pre-formed substrate is opaque.

14. The building structure as recited in claim 9, wherein the one or more architectural panels further comprise:

at least one tie layer positioned between the pre-formed translucent substrate and the encapsulation film of the one or more organic photovoltaic components;

the at least one tie layer adhering the pre-formed translucent substrate to the encapsulation film of the one or more organic photovoltaic components.

15. The building structure as recited in claim 9, wherein the pre-formed translucent substrate includes a texture on an upper surface thereof.

16. The building structure as recited in claim 9, wherein the one or more translucent, organic photovoltaic components have a diagonal orientation relative to the pre-formed translucent substrate.

17. The building structure as recited in claim 9, wherein the one or more translucent, organic photovoltaic components are at least a first distance from each edge of an upper surface of the pre-formed translucent substrate.

18. The building structure as recited in claim 17, wherein the barrier layer is positioned at least a second distance from each edge of the upper surface of the pre-formed translucent substrate, wherein the first distance is greater than the second distance.

21. A translucent, laminate panel configured for photovoltaic power-generation, and having sufficient rigidity and strength for use as a solar power-generating building material or component, the laminate panel comprising:

a first rigid, pre-formed substrate having been formed into a non-linear shape, and being sufficiently rigid and inflexible for use as a building material;

one or more flexible organic photovoltaic components fused to the first rigid, pre-formed substrate, wherein the one or more flexible organic photovoltaic components conform to the non-linear shape of the first rigid, pre-formed substrate;

wherein the one or more flexible organic photovoltaic components comprise one or more photovoltaic cells adhered within an encapsulation film, such that the encapsulation film insulates the flexible, organic photovoltaic components within the encapsulation film and prevents degradation of the photovoltaic components; and

a second rigid, pre-formed substrate having been formed into the same non-linear shape as the first rigid, pre-formed substrate, wherein the second rigid, pre-formed substrate is translucent, and is fused at least to the encapsulating film of the one or more flexible organic photovoltaic components;

wherein the first and second rigid pre-formed substrates and one or more organic photovoltaic components form a substantially rigid panel that is sufficiently strong and rigid for use as a building material, as a shield from outside elements, and is suited for use as photovoltaic power generator.

22. The laminate panel as recited in claim 21, further comprising one or more tie layers fused to at least one of the rigid first or second pre-formed substrates and at least one of the one or more photovoltaic components.

23. The laminate panel as recited in claim 21, wherein at least one of the organic photovoltaic components is translucent, such that the at least one translucent organic photovoltaic component and second rigid pre-formed substrate allow light to pass through.

24. The laminate panel as recited in claim 23, wherein the first pre-formed substrate is translucent, such that each of the rigid pre-formed substrates and translucent organic photovoltaic components allow light to pass through the fused layers.

25. The laminate panel as recited in claim 23, wherein:

the second rigid pre-formed substrate is substantially thinner gauge than the first rigid pre-formed substrate;

the thinner gauge of the second rigid pre-formed substrate is configured to maximize solar power-generating ability without compromising strength or durability of the resultant laminate pane; and

the resulting panel has an asymmetrical configuration.