Photovoltaic modules for use in vehicle roofs, and/or methods of making the same

• US 8,834,664 B2
• Filed: 04/18/2012
• Issued: 09/16/2014
• Est. Priority Date: 10/22/2010
• Status: Expired due to Fees

• Current Assignee: Guardian Glass LLC (KOCH Industries Incorporated)
• Original Assignee: Guardian Industries Corporation (KOCH Industries Incorporated)
• Inventors: Brecht, Greg, Ruggero, Vincent E. II, Frey, Timothy J., Vandal, Robert A.
• Primary Examiner(s): PERT, EVAN T
• Application Number:
  US13/449,623
• Publication Number:
  US 20120260974A1
• Time in Patent Office: 881 Days
• Field of Search: 156/251, 156/259, 438/64, 438/65, 438/71, 438/98, 257/434
• US Class Current: 156/251
• CPC Class Codes: B32B 17/10036 comprising two outer glass sheets
• CPC Class Codes: B32B 17/10119 having a composition deviating from the basic composition of soda-lime glass, e.g. borosilicate
• CPC Class Codes: B32B 17/10761 containing vinyl acetal
• CPC Class Codes: B32B 17/10788 containing ethylene vinylacetate
• CPC Class Codes: B32B 2457/12 Photovoltaic modules
• CPC Class Codes: C03B 23/025 by gravity
• CPC Class Codes: H01L 31/0488 Double glass encapsulation, e.g. photovoltaic cells arranged between front and rear glass sheets
• CPC Class Codes: Y02E 10/50 Photovoltaic [PV] energy
• CPC Class Codes: Y02T 10/88 Optimized components or subsystems, e.g. lighting, actively controlled glasses
• CPC Class Codes: Y02T 10/90 Energy harvesting concepts as power supply for auxiliaries' energy consumption, e.g. photovoltaic sun-roof
• CPC Class Codes: Y10T 156/1054 and simultaneously bonding [e.g., cut-seaming]
• CPC Class Codes: Y10T 156/1067 Continuous longitudinal slitting

Abstract

Certain example embodiments relate to techniques for creating improved photovoltaic (PV) modules. In certain example embodiments and first and second glass substrate are provided. A PV array is provided between the first and second glass substrates. The first and second substrates are laminated together with the PV array between the glass substrates. In certain example embodiments the PV module is dimensioned to be similar to an existing roof system (e.g., a sunroof) in a vehicle. In certain example embodiments, holes are provided in a PV module sandwiched between two substrates, the holes being shaped and arranged within the PV module so as to allow light transmission into the vehicle at desired level while still being substantially filled by the laminate or adhesive material used to secure the PV module to the two surrounding substrates.

Claims

1. A method of making an integrated photovoltaic (PV) module for use in a vehicle, the method comprising:

providing first and second glass substrates;

providing a PV module, the PV module having a plurality of through-holes formed therein;

laminating together the first and second glass substrates with the PV module therebetween; and

wherein during said laminating, laminating material is allowed to at least substantially fill the plurality of through-holes in the PV module as a result of the through-holes'"'"' size, shape, and placement, and

wherein the through-holes collectively have a total area selected so as to allow visible transmission through the integrated PV module to reach a selected target value.

2. The method of claim 1, wherein the target value is 10%.

3. The method of claim 1, wherein the PV module includes a plurality of spaced apart solar cells.

4. The method of claim 3, wherein the solar cells are separated by a grid of conductive material.

5. The method of claim 4, wherein the through-holes are spaced from lines of the grid at a distance sufficient to prevent electrical shorts.

6. The method of claim 5, wherein the distance is at least about 1 mm.

7. The method of claim 4, wherein the through-holes are substantially centered within cells of the grid.

8. The method of claim 4, wherein at least some of through-holes are located between adjacent solar cells.

9. The method of claim 4, wherein at least some of the through-holes are located at a peripheral edge of the PV module, and are closer to the peripheral edge than any solar cells.

10. The method of claim 3, further comprising connecting a plurality of bus bars to the PV module.

11. The method of claim 1, wherein the through-holes each are generally elongate and have rounded corners.

12. A method of making a vehicle, the method comprising:

providing an integrated photovoltaic (PV) module made by the method of claim 1; and

building the integrated PV module into the vehicle.

13. A method of making a photovoltaic (PV) module, the method comprising:

providing a substrate with a plurality of solar cells formed thereon;

providing a grid of conductive material on the substrate;

forming a plurality of through-holes in the substrate in a pattern such that (a) the through-holes collectively have a total area selected so as to allow visible transmission through an integrated PV module in which the PV module is disposed to reach a selected target value, and (b) the through-holes have an aspect ratio and a positioning sufficient to allow laminating material used in making the integrated PV module to flow therein and substantially fill the through-holes.

14. The method of claim 13, wherein the through-holes are formed by laser cutting.

15. The method of claim 13, wherein the solar cells are CIGS-type solar cells.

16. An integrated photovoltaic (PV) module for use in a vehicle, comprising:

first and second glass substrates;

a PV module including a plurality of spaced apart solar cells and having a plurality of through-holes formed therein, the PV module being interposed between the first and second glass substrates; and

a plurality of collection lines formed on the substrate and between adjacent solar cells,

wherein the PV module is laminated to the first and second substrates such that the plurality of through-holes in the PV module are substantially filled with laminating material as a result of the through-holes'"'"' size, shape, and placement, and

wherein the through-holes collectively have a total area selected so as to allow visible transmission through the integrated PV module to reach a selected target value.

17. The module of claim 16, wherein the through-holes are spaced from lines of the grid at a distance sufficient to prevent electrical shorts.

18. The module of claim 16, wherein the through-holes are substantially centered within cells of the grid.

19. The module of claim 16, wherein:

a first subset of the through-holes are located between adjacent solar cells, and

a second subset of the through-holes are located at a peripheral edge of the PV module, and are closer to the peripheral edge than any solar cells.

20. The module of claim 16, wherein the laminating material is PVB.

21. The module of claim 16, wherein the solar cells are CIGS-type solar cells.

22. The module of claim 16, wherein the second glass substrate has more iron than the first glass substrate.

23. A sunroof comprising the integrated photovoltaic (PV) module of claim 16.