DE102004003328B4 - Method for producing a curved body element with solar cells - Google Patents

Method for producing a curved body element with solar cells Download PDF

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Publication number
DE102004003328B4
DE102004003328B4 DE102004003328A DE102004003328A DE102004003328B4 DE 102004003328 B4 DE102004003328 B4 DE 102004003328B4 DE 102004003328 A DE102004003328 A DE 102004003328A DE 102004003328 A DE102004003328 A DE 102004003328A DE 102004003328 B4 DE102004003328 B4 DE 102004003328B4
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solar cells
body element
melt adhesive
hot melt
curvature
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DE102004003328A
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DE102004003328A1 (en
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Helmut Teschner
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Webasto SE
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Webasto SE
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/18—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure using heated tools
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B29C66/433—Casing-in, i.e. enclosing an element between two sheets by an outlined seam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B1/00—Layered products having a non-planar shape
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/10009—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets
    • B32B17/10018—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the number, the constitution or treatment of glass sheets comprising only one glass sheet
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
    • B32B17/10743—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer containing acrylate (co)polymers or salts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/1055—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer
    • B32B17/10788—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing characterized by the resin layer, i.e. interlayer containing ethylene vinylacetate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/10807—Making laminated safety glass or glazing; Apparatus therefor
    • B32B17/10816—Making laminated safety glass or glazing; Apparatus therefor by pressing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B17/00—Layered products essentially comprising sheet glass, or glass, slag, or like fibres
    • B32B17/06—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material
    • B32B17/10—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin
    • B32B17/10005—Layered products essentially comprising sheet glass, or glass, slag, or like fibres comprising glass as the main or only constituent of a layer, next to another layer of a specific material of synthetic resin laminated safety glass or glazing
    • B32B17/10807—Making laminated safety glass or glazing; Apparatus therefor
    • B32B17/10816—Making laminated safety glass or glazing; Apparatus therefor by pressing
    • B32B17/10871—Making laminated safety glass or glazing; Apparatus therefor by pressing in combination with particular heat treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/306—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl acetate or vinyl alcohol (co)polymers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/048—Encapsulation of modules
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
    • H02S10/00—PV power plants; Combinations of PV energy systems with other systems for the generation of electric power
    • H02S10/40—Mobile PV generator systems
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2457/00—Electrical equipment
    • B32B2457/12—Photovoltaic modules
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/08—Cars
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00—Energy generation through renewable energy sources
    • Y02E10/50—Photovoltaic [PV] energy
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/80—Technologies aiming to reduce greenhouse gasses emissions common to all road transportation technologies
    • Y02T10/90—Energy harvesting concepts as power supply for auxiliaries' energy consumption, e.g. photovoltaic sun-roof

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Condensed Matter Physics & Semiconductors (AREA)
  • Electromagnetism (AREA)
  • General Physics & Mathematics (AREA)
  • Computer Hardware Design (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Power Engineering (AREA)
  • Thermal Sciences (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)

Abstract

Verfahren zum Herstellen eines in mindestens einer Richtung gewölbten Karosserieelements (10) für ein Fahrzeug, wobei auf eine Seite des Karosserieelements eine erste Schmelzklebefolie (16) aufgelegt wird, auf die erste Schmelzklebefolie ein flächiger Verbund aus mehreren planen Solarzellen (18A, 18B, 18C) aufgelegt wird, auf den Solarzellenverbund eine zweite Schmelzklebefolie (20) aufgelegt wird, mittels einer Matrize (24) Druck auf die zweite Schmelzklebefolie ausgeübt wird, und der so gebildete Folienverbund einer Wärmebehandlung erzogen wird, um den Solarzellenverbund mit dem Karosserieelement zu laminieren, und nach dem Laminieren die Matrize (24) abgenommen wird, dadurch gekennzeichnet, dass die auf den Solarzellenverbund Druck ausübende Oberfläche der Matrize aus ebenen Flächen (28A, 28B, 28C) zusammengesetzt ist, die im Schnitt entlang der Wölbungsrichtung als ein die Wölbung des Karosserieelements (10) nachbildender Polygonzug (26) ausgebildet sind, um eine die Wölbung des Karosserieelements nachbildende, im Schnitt entlang der Wölbungsrichtung polygonzugartige Anordnung der Solarzellen (18A, 18B, 18C) nach dem Laminieren zu...method for producing a body element (10) arched in at least one direction for a Vehicle, wherein on one side of the body member a first Hot melt adhesive film (16) is applied to the first hot melt adhesive film a plane Composite of several planar solar cells (18A, 18B, 18C) is launched, placed on the solar cell composite, a second hot melt adhesive film (20) is, by means of a die (24) pressure on the second hot melt adhesive film exercised and the film composite thus formed is subjected to a heat treatment, to laminate the solar cell composite with the body element, and after lamination, the female die (24) is removed thereby in that the pressure acting on the solar cell composite surface of the Matrix of flat surfaces (28A, 28B, 28C) which are arranged in section along the curvature direction as a the vault formed of the body member (10) replicating traverse (26) are to the a buckle of the body element reproducing, in section along the curvature direction polygonzugartige arrangement of the solar cells (18A, 18B, 18C) according to lamination to ...

Figure 00000001
Figure 00000001

Description

Die vorliegende Erfindung betrifft ein Verfahren zum Herstellen eines mindestens in einer Richtung gewölbten Karosserieelements für ein Fahrzeug mit Solarzellen gemäß dem Oberbegriff von Anspruch 1.The The present invention relates to a method for producing a arched at least in one direction Body element for a vehicle with solar cells according to the preamble of claim 1.

Transparente Karosserieelemente, insbesondere die Form von Glasscheiben im Dachbereich, z.B. in Form von Solardeckeln, mit an der Unterseite angebrachten Solarzellen, sind im Fahrzeugbereich seit längerem bekannt. Dabei werden die Solarzellen als flächiger Verbund üblicherweise zwischen der Unterseite der Scheibe und einem Abdeckelement zwischen Schmelzklebefolien einlaminiert, siehe z.B. DE 197 16 389 C1 , DE 101 27 847 A1 , DE 199 37 221 C1 , oder DE 198 13 324 A1 .Transparent body elements, in particular the shape of glass panes in the roof area, for example in the form of solar lids, with solar cells mounted on the underside, have long been known in the field of vehicles. The solar cells are laminated as a flat composite usually between the bottom of the disc and a cover between hot melt adhesive films, see, for example DE 197 16 389 C1 . DE 101 27 847 A1 . DE 199 37 221 C1 , or DE 198 13 324 A1 ,

Ein Herstellungsverfahren für eine gewölbte Scheibe ist in der EP 0 221 287 B1 beschrieben, wo die Herstellung eines Solardeckels mit einer gewölbten Scheibe beschrieben ist, wobei ein flächiger Solarzellenverbund zwischen zwei Schmelzklebefolien zwischen der Unterseite der Scheibe und einem entsprechend gewölbten Träger einlaminiert wird. Während des Laminationsvorgangs werden die Solarzellen und die Schmelzklebefolien durch äußeren mechanischen Druck auf den Träger und die Glasscheibe der Wölbung des Gesamtverbunds angepasst. Nachteilig bei diesem Verfahren ist, dass die Solarzellen während des Laminationsvorgangs und auch danach durch die Wirkung des gewölbten Trägers entsprechend der Wölbung der Scheibe und des Trägers gebogen sind, was zu einer erhebliche Bruchgefahr der Solarzellen führen kann.A manufacturing method for a domed disc is in the EP 0 221 287 B1 describes where the production of a solar cover is described with a curved disc, wherein a flat solar cell assembly between two hot melt adhesive films between the bottom of the disc and a correspondingly curved support is laminated. During the lamination process, the solar cells and the hot melt adhesive films are adapted by external mechanical pressure on the support and the glass pane of the curvature of the overall composite. A disadvantage of this method is that the solar cells are bent during the lamination process and also thereafter by the action of the curved support according to the curvature of the disc and the support, which can lead to a considerable risk of fracture of the solar cell.

Ein Herstellungsverfahren gemäß dem Oberbegriff von Anspruch 1 ist aus der JP 03-204979 A bekannt.One Production method according to the preamble of claim 1 is known from JP 03-204979 A.

In der CH 683730 A5 ist ein Verfahren zum Herstellen eines photovoltaischen Solarmoduls für ein Fahrzeug beschrieben, wobei in eine vorgekrümmte Frontglasscheibe zunächst Klebertropfen gegeben werden und darauf die Solarzellen gedrückt werden, und wobei, um ein Zerbrechen der Zellen beim Eindrücken zu verhindern, die Zellen mit der Rückseite ganzflächig auf einer geeigneten Stützfläche der Zellenhalterung aufliegen sollen.In the CH 683730 A5 is described a method for producing a photovoltaic solar module for a vehicle, wherein in a pre-curved front glass pane are first given drops of adhesive and then the solar cells are pressed, and wherein, in order to prevent breakage of the cells when pressed, the cells with the back over the entire surface on a suitable support surface of the cell holder to rest.

In der WO 03/069682 A2 ist ein Verfahren zum Herstellen eines gekrümmten Solarmoduls beschrieben, wobei kristalline Solarzellen mit einer Dicke von 200 μm oder weniger auf einer gekrümmten dünnen Metallplatte befestigt werden.In WO 03/069682 A2 is a method for producing a curved solar module described, wherein crystalline solar cells having a thickness of 200 microns or less on a curved thin metal plate be attached.

Aus der DE 102 18 198 C1 ist ein Verfahren zum Herstellen eines Solarmoduls für ein Kraftfahrzeugdach bekannt, wobei zur Herstellung eines Glas-Solarzellen-Laminats ein Laminator mit konkav gewölbter Heizplatte und Deckel mit einem Diaphragma verwendet wird.From the DE 102 18 198 C1 a method for producing a solar module for a motor vehicle roof is known, wherein for the production of a glass-solar cell laminate, a laminator with concave heating plate and lid with a diaphragm is used.

Aus der US 3,565,719 ist ein Verfahren zur Herstellung eines gekrümmten Solarmoduls beschrieben, wobei die in einem entfernbaren Träger gehalterten Solarzellen in eine Klebstoffschicht gedrückt werden, um die Solarzellen mit einem dann permanenten Träger zu verbinden, und wobei der Verbindungsdruck mittels einer evakuierbaren Tasche erzeugt wird.From the US 3,565,719 there is described a method of making a curved solar module wherein the solar cells supported in a removable support are forced into an adhesive layer to bond the solar cells to a then permanent support and wherein the bonding pressure is created by means of an evacuatable pocket.

Aus der DE 33 00 622 A1 ist eine Vorrichtung zur Herstellung eines planaren Solarmoduls bekannt, wobei die Vorrichtung eine obere Heizplatte aufweist, die in vertikaler Richtung bewegbar und durch Anschläge bzw. den zu pressenden Schichtkörper kippbar ist, wodurch die Pressplatten der oberen Heizplatte in einer unteren Heizplatte ein Trapez bilden.From the DE 33 00 622 A1 a device for producing a planar solar module is known, wherein the device has an upper heating plate which is movable in the vertical direction and tiltable by stops or the laminated body to be pressed, whereby the pressure plates of the upper heating plate in a lower heating plate form a trapezoid.

Es ist Aufgabe der vorliegenden Erfindung, ein Herstellungsverfahren für ein gewölbtes Karosserieelement für ein Fahrzeug mit einem Solarzellenverbund zu schaffen, wobei die Bruchgefahr der Solarzelle möglichst gering gehalten werden soll.It The object of the present invention is a production process for a domed Body element for to provide a vehicle with a solar cell assembly, wherein the Danger of fracture of the solar cell if possible should be kept low.

Diese Aufgabe wird erfindungsgemäß gelöst durch ein Verfahren gemäß Anspruch 1. Dabei ist vorteilhaft, dass dadurch, dass die auf den Solarzellenverbund Druck ausübende Oberfläche der Matrize aus ebenen Flächen zusammengesetzt ist, die im Schnitt entlang der Wölbungsrichtung als ein die Wölbung des Karosserieelements nachbildender Polygonzug ausgebildet sind, nach dem Laminieren eine Anordnung der Solarzellen erreicht werden kann, welche die Wölbung des Karosserieelements nachbildet und im Schnitt entlang der Wölbungsrichtung polygonzugartig ist, wodurch eine Biegebelastung der einzelnen Solarzellen trotz Nachbildung der Wölbung des Karosserieelements vermieden werden kann. Dadurch kann die Bruchgefahr der Solarzellen während des Herstellungsverfahrens stark verringert werden.These The object is achieved by a method according to claim 1. It is advantageous that the fact that the on the solar cell assembly Pressure exercising surface the matrix of flat surfaces is composed, in section along the curvature direction as a the vault are formed of the body element replicating traverse, After lamination, an arrangement of the solar cells can be achieved can, which the vaulting of the body element and in the section along the curvature direction polygonzugartig is, whereby a bending load of the individual solar cells despite Replica of the vault of the body element can be avoided. This can break the risk the solar cells during of the manufacturing process are greatly reduced.

Bevorzugte Ausgestaltungen der Erfindung sind in den Unteransprüchen angegeben.preferred Embodiments of the invention are specified in the subclaims.

Im folgenden wird die Erfindung anhand der beigefügten einzigen Zeichnung beispielhaft näher erläutert, welche eine Querschnittansicht einer gewölbten Scheibe während des Auflaminierens eines Solarzellenverbunds in einem Laminator zeigt.in the The following is an example of the invention with reference to the accompanying single drawing explains in more detail which a cross-sectional view of a curved disc during the Lamination of a solar cell composite in a laminator shows.

Gemäß der einzigen Figur wird eine in mindestens einer Richtung gewölbte Scheibe 10 auf eine gewölbte Matrize 12 aufgelegt, deren konkave Oberfläche sich an die konvexe Außenfläche der Scheibe 10 anschmiegt, um die Scheibe 10 während des Laminationsvorgangs abzustützen. Die Matrize 12 ist auf der Heizplatte 14 eines Laminators angeordnet, um mittels Wärmeleitung über die Matrize 12 die Scheibe 10 und die darauf aufgelegten Folien zu beheizen.According to the single figure is a curved in at least one direction disc 10 on a domed matrix 12 its concave surface is attached to the convex outer surface of the disc 10 clings to the disc 10 during the lamination process. The matrix 12 is on the hot plate 14 a laminator arranged to conduct by heat conduction through the die 12 the disc 10 and to heat the slides placed thereon.

Auf die konkave Innenseite der Scheibe 10 wird eine erste Schmelzklebefolie 16 aufgelegt, auf welche dann ein flächiger Verbund aus mehreren Solarzellen 18A, 18B, 18C aufgelegt wird. Auf den Verbund der Solarzellen 18A, 18B, 18C wird eine zweite Schmelzklebefolie 20 aufgelegt, auf welche wiederum eine vorzugsweise nicht transparente Deckfolie 22 aufgelegt wird.On the concave inside of the disc 10 becomes a first hot melt adhesive film 16 placed on which then a two-dimensional composite of several solar cells 18A . 18B . 18C is hung up. On the network of solar cells 18A . 18B . 18C becomes a second hot melt adhesive film 20 placed on which in turn a preferably non-transparent cover sheet 22 is hung up.

Auf den auf diese Weise gebildeten Folienverbund wird schließlich eine Matrize 24 aufgelegt, deren Oberfläche aus einer Mehrzahl von ebenen Flächen zusammengesetzt ist, die im Schnitt entlang der Wölbungsrichtung der Glasscheibe 10 als ein die Wölbung der Glasscheibe 10 nachbildender Polygonzug 26 ausgebildet sind. In der Figur sind diese ebenen Flächen des Polygonzugs 26 mit 28A, 28B bzw. 28C bezeichnet. Im gezeigten Beispiel sind die einzelnen ebenen Flächen, 28A, 28B bzw. 28C so bemessen, dass sie jeweils einer einzigen der Solarzellen zugeordnet sind, um während des Laminationsvorgangs auf diese zugeordnete Solarzelle 18A, 18B bzw. 18C Druck auszuüben. Dabei ordnet sich jede Solarzelle 18 im wesentlichen parallel zu der zugeordneten ebenen Fläche 28A, 28B bzw. 28C an. Dies wird dadurch ermöglicht, dass die Schmelzklebefolien 16 und 20 durch die Temperatureinwirkung während des Aufheizens durch die Heizplatte 14 schmelzen und eine zähflüssige Konsistenz annehmen. Während des Laminationsvorgangs vernetzen bzw. vulkanisieren die Schmelzklebefolien 16 und 20 allmählich, wodurch die Solarzellen 18A, 18B, 18C schließlich in der in der Figur gezeigten Position, in welcher sie im wesentlichen parallel zu der jeweiligen ebenen Fläche 28a, 28B bzw. 28C der Matrize 24 angeordnet sind, fixiert werden.On the film composite formed in this way is finally a die 24 placed, the surface of which is composed of a plurality of flat surfaces, which in section along the curvature direction of the glass sheet 10 as a the curvature of the glass pane 10 simulating traverse 26 are formed. In the figure, these are flat surfaces of the traverse 26 With 28A . 28B respectively. 28C designated. In the example shown, the individual flat surfaces, 28A . 28B respectively. 28C so dimensioned that they are each assigned to a single one of the solar cells to during the lamination process on this associated solar cell 18A . 18B respectively. 18C Exercise pressure. Here, every solar cell is arranged 18 substantially parallel to the associated flat surface 28A . 28B respectively. 28C at. This is made possible by the fact that the hot melt adhesive films 16 and 20 by the effect of temperature during heating by the heating plate 14 melt and assume a viscous consistency. During the lamination process, the hot melt adhesive films crosslink or vulcanize 16 and 20 gradually, causing the solar cells 18A . 18B . 18C finally, in the position shown in the figure, in which they are substantially parallel to the respective flat surface 28a . 28B respectively. 28C the matrix 24 are arranged to be fixed.

Auf diese Weise sind die Solarzellen 18A, 18B, 18C nach dem Laminieren krümmungsfrei bzw. biegespannungsfrei in die Schmelzklebefolien 16 bzw. 20 zwischen der Scheibe 10 und der Deckfolie 22 eingebettet, wobei die Solarzellen 18A, 18B, 18C eine polygonzugartige Anordnung einnehmen, welche die Wölbung der Scheibe 10 nachbildet. Jede einzelne Solarzelle 18 ist dabei eben und flach, d.h. nicht gekrümmt, ausgebildet.That's how the solar cells are 18A . 18B . 18C after laminating without bending or without bending stress into the hot-melt adhesive films 16 respectively. 20 between the disc 10 and the cover sheet 22 embedded, with the solar cells 18A . 18B . 18C take a polygonal pull-like arrangement, which the curvature of the disc 10 replicates. Every single solar cell 18 is flat and flat, ie not curved, formed.

Bei den Schmelzklebefolien 16, 20 handelt es sich vorzugsweise um EVA-Folien.For the hot melt adhesive films 16 . 20 these are preferably EVA films.

Während des Laminationsvorgangs wird der Folienverbund im Laminator evakuiert, um Lufteinschlüsse und damit eine Beeinträchtigung der optischen Qualität des Laminats zu vermeiden. Gleichzeitig wird auf die Matrize 24 ein zu der Scheibe 10 hin wirkender Druck ausgeübt, um die Solarzellen 18A, 18B, 18C in die gezeigte polygonzugartige Anordnung zu bringen. Nach dem Ende des Laminationsvorgangs wird die Matrize 24 nach oben abgehoben.During the lamination process, the film composite in the laminator is evacuated in order to avoid air pockets and thus a deterioration of the optical quality of the laminate. At the same time, on the die 24 one to the disc 10 acting pressure applied to the solar cells 18A . 18B . 18C to bring in the polygonzugartige arrangement shown. After the end of the lamination process, the die becomes 24 lifted off to the top.

Die in der Figur gezeigte Scheibe kann zusätzlich zu der Krümmung in der Richtung des dargestellten Querschnitts auch in der Richtung senkrecht dazu gekrümmt sein (d.h. in einer Richtung senkrecht zu der Papierebene). In diesem Fall ist die Matrize 24 auch in der Richtung senkrecht zu der gezeigten Querschnittsrichtung im Querschnitt entlang der zweiten Wölbungsrichtung als ein die Wölbung der Scheibe 10 in diese zweite Richtung nachbildender Polygonzug ausgebildet (d.h. die ebenen Flächen 28A usw. sind im Schnitt als entsprechender Polygonzug ausgebildet). Als Ergebnis wird beim Laminationsvorgang erreicht, dass die Solarzellen 18A, 18B, 18C auch in dieser zweiten Wölbungsrichtung polygonzugartig angeordnet sind, um die Wölbung der Scheibe 16 in dieser zweiten Richtung nachzubilden.The disc shown in the figure may be curved in the direction perpendicular thereto (ie, in a direction perpendicular to the paper plane) in addition to the curvature in the direction of the illustrated cross section. In this case, the die is 24 also in the direction perpendicular to the cross-sectional direction shown in cross-section along the second curvature direction as the curvature of the disc 10 formed in this second direction simulating traverse (ie, the flat surfaces 28A etc. are formed on average as a corresponding traverse). As a result, the lamination process achieves that the solar cells 18A . 18B . 18C Also in this second buckling direction are arranged polygonal, to the curvature of the disc 16 to replicate in this second direction.

In dem in der Figur gezeigten Beispiel sind die ebenen Flächen 28A, 28B und 28C der Matrize 24 so ausgebildet, dass sie jeweils einer einzelnen der Solarzellen 18A, 18B, 18C zugeordnet sind und nur auf diese Druck ausüben. Bei abgewandelten Ausführungsformen ist es jedoch unter Umständen auch denkbar, die ebenen Flächen der Matrize so zu gestalten, dass sie jeweils mehreren benachbarten Solarzellen zugeordnet sind und auf diese Druck ausüben. Nach dem Laminieren liegen dann diese einer bestimmten der ebenen Flächen zugeordneten benachbarten Solarzellen im wesentlichen in einer Ebene.In the example shown in the figure, the flat surfaces are 28A . 28B and 28C the matrix 24 designed so that each one of the solar cells 18A . 18B . 18C are assigned and only apply to this pressure. In modified embodiments, however, it is also conceivable under certain circumstances to make the flat surfaces of the die so that they are each assigned to a plurality of adjacent solar cells and exert pressure on them. After lamination, these adjacent solar cells assigned to one of the flat surfaces lie substantially in one plane.

Bei der in der Figur gezeigten Ausführungsform sind die Solarzellen 18A, 18B, 18C auf der konkaven Innenseite der Scheibe 10 angeordnet. Grundsätzlich wäre es jedoch auch denkbar, die Solarzellen 18A, 18B, 18C auf der konvexen Außenseite der Scheibe 10 anzuordnen, wobei in diesem Fall die den Druck ausübende Oberfläche der Matrize konkav, d.h. als konkaver Polygonzug, ausgebildet sein muss.In the embodiment shown in the figure, the solar cells are 18A . 18B . 18C on the concave inside of the disc 10 arranged. In principle, however, it would also be conceivable, the solar cells 18A . 18B . 18C on the convex outside of the disc 10 to be arranged, in which case the pressure-exerting surface of the die must be concave, ie, designed as a concave traverse.

Bei der Scheibe 10 handelt es sich vorzugsweise um eine mindestens teilweise transparente Scheibe aus Glas oder Kunststoff, die mindestens einen Teil eines Fahrzeugdaches bildet. Dabei kann die Scheibe 10 einen Teil eines verstellbaren Deckels für eine Dachöffnung oder einen karosseriefest eingebauten Deckel bilden.At the disc 10 it is preferably an at least partially transparent pane of glass or plastic, which forms at least part of a vehicle roof. In doing so, the disc can 10 a part of an adjustable cover for form a roof opening or a body-mounted lid.

Grundsätzlich ist die Erfindung jedoch nicht auf die Herstellung einer Scheibe für den Dachbereich beschränkt. So kann das erfindungsgemäße Verfahren auch zur Lamination eines Solarzellenverbunds auf ein anderes Karosserieelement verwendet werden, beispielsweise auf eine Heckscheibe, eine Motorhaube, eine Heckklappe oder einen Spoiler. Falls die Solarzellen auf die Außenseite des Karosserieelements auflaminiert werden, muß das Karosserieelement auch nicht transparent sein.Basically However, the invention does not relate to the production of a pane for the roof area limited. Thus, the inventive method also for lamination of a solar cell composite to another body element used, for example, on a rear window, a hood, a tailgate or a spoiler. If the solar cells on the outside of the body member are laminated, the body member must also not be transparent.

1010
Scheibedisc
1212
Matrizedie
1414
Heizplatteheating plate
1616
SchmelzklebefolieMelt adhesive film
18A,18B,18C18A, 18B, 18C
Solarzellensolar cells
2020
SchmelzklebefolieMelt adhesive film
2222
Deckfoliecover sheet
2424
Matrizedie
2626
Polygonzug-Schnitt von 24 Traverse section of 24
28A,28B,28C28A, 28B, 28C
ebene Flächen von 24, im Schnittflat surfaces of 24 , on average

Claims (12)

Verfahren zum Herstellen eines in mindestens einer Richtung gewölbten Karosserieelements (10) für ein Fahrzeug, wobei auf eine Seite des Karosserieelements eine erste Schmelzklebefolie (16) aufgelegt wird, auf die erste Schmelzklebefolie ein flächiger Verbund aus mehreren planen Solarzellen (18A, 18B, 18C) aufgelegt wird, auf den Solarzellenverbund eine zweite Schmelzklebefolie (20) aufgelegt wird, mittels einer Matrize (24) Druck auf die zweite Schmelzklebefolie ausgeübt wird, und der so gebildete Folienverbund einer Wärmebehandlung erzogen wird, um den Solarzellenverbund mit dem Karosserieelement zu laminieren, und nach dem Laminieren die Matrize (24) abgenommen wird, dadurch gekennzeichnet, dass die auf den Solarzellenverbund Druck ausübende Oberfläche der Matrize aus ebenen Flächen (28A, 28B, 28C) zusammengesetzt ist, die im Schnitt entlang der Wölbungsrichtung als ein die Wölbung des Karosserieelements (10) nachbildender Polygonzug (26) ausgebildet sind, um eine die Wölbung des Karosserieelements nachbildende, im Schnitt entlang der Wölbungsrichtung polygonzugartige Anordnung der Solarzellen (18A, 18B, 18C) nach dem Laminieren zu erzielen.Method for producing a body element arched in at least one direction ( 10 ) for a vehicle, wherein on one side of the body element a first hot melt adhesive film ( 16 ) is laid on the first hot melt adhesive sheet a laminar composite of several flat solar cells ( 18A . 18B . 18C ) is applied to the solar cell composite, a second hot melt adhesive film ( 20 ) is applied by means of a die ( 24 ) Is applied to the second hot melt adhesive film, and the film composite thus formed is subjected to a heat treatment in order to laminate the solar cell composite with the body element, and after the lamination process the matrix ( 24 ), characterized in that the surface of the matrix exerting pressure on the solar cell assembly consists of flat surfaces ( 28A . 28B . 28C ), which in section along the curvature direction as the curvature of the body element ( 10 ) Tracing Traverse ( 26 ) are formed to a the curvature of the body element replicating, in the section along the curvature direction polygonzugartige arrangement of the solar cells ( 18A . 18B . 18C ) after lamination. Verfahren gemäß Anspruch 1, dadurch gekennzeichnet, dass vor dem Laminieren eine Deckfolie (22) zwischen die zweite Schmelzklebefolie (20) und die Matrize (24) eingelegt wird.A method according to claim 1, characterized in that before laminating a cover sheet ( 22 ) between the second hot melt adhesive film ( 20 ) and the die ( 24 ) is inserted. Verfahren gemäß Anspruch 1 oder 2, dadurch gekennzeichnet, dass die Schmelzklebefolien (16, 20) von EVA-Folien gebildet werden.A method according to claim 1 or 2, characterized in that the hot melt adhesive films ( 16 . 20 ) of EVA films are formed. Verfahren gemäß einem der vorhergehenden Ansprüche; dadurch gekennzeichnet, dass während das Laminierens die von den Solarzellen (18A, 18B, 18C) weg weisende Seite des Karosserieelements (10) von einer sich an die Wölbung des Karosserieelements anschmiegenden Matrize (12) abgestützt wird.Method according to one of the preceding claims ; characterized in that during lamination, that of the solar cells ( 18A . 18B . 18C ) side facing away from the bodywork element ( 10 ) of a conforming to the curvature of the body element die ( 12 ) is supported. Verfahren gemäß einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass das Laminieren in einem Laminator mit einer Heizplatte (14) ausgeführt wird.Method according to one of the preceding claims, characterized in that the lamination in a laminator with a heating plate ( 14 ) is performed. Verfahren gemäß einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass die Folien (16, 20, 22) und die Solarzellen 18A, 18B, 18C) auf die konkave Seite des Karosserieelements (10) gelegt werden und die Matrizenoberfläche (28A, 28B, 28C) konvex geformt ist.Method according to one of the preceding claims, characterized in that the films ( 16 . 20 . 22 ) and the solar cells 18A . 18B . 18C ) on the concave side of the body element ( 10 ) and the die surface ( 28A . 28B . 28C ) is convex. Verfahren gemäß einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass die Folien (16, 20, 22) und die Solarzellen (18A, 18B, 18C) auf die nach innen weisende Seite des Karosserieelements (10) gelegt werden.Method according to one of the preceding claims, characterized in that the films ( 16 . 20 . 22 ) and the solar cells ( 18A . 18B . 18C ) on the inwardly facing side of the body member ( 10 ) be placed. Verfahren gemäß einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass die Solarzellen (18A, 18B, 18C) nach dem Laminieren krümmungfrei in die Schmelzklebefolien (16, 20) eingebettet sind.Method according to one of the preceding claims, characterized in that the solar cells ( 18A . 18B . 18C ) after lamination free of curvature in the hot melt adhesive films ( 16 . 20 ) are embedded. Verfahren gemäß einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass jede ebene Fläche (28A, 28B, 28C) der auf die Solarzellen (18A, 18B, 18C) Druck ausübenden Matrize (24) so bemessen ist, um Druck auf eine einzige Solarzelle auszuüben.Method according to one of the preceding claims, characterized in that each flat surface ( 28A . 28B . 28C ) on the solar cells ( 18A . 18B . 18C ) Pressure applying die ( 24 ) is sized to apply pressure to a single solar cell. Verfahren gemäß einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass das Karosserieelement (10) in zwei zueinander senkrechte Richtungen gewölbt ist, wobei die auf die Solarzellen (18A, 18B, 18C) Druck ausübende Oberfläche der Matrize (24) im Schnitt entlang beider Wölbungsrichtungen als ein die jeweilige Wölbung des Karosserieelements nachbildender Polygonzug ausgebildet ist.Method according to one of the preceding claims, characterized in that the body element ( 10 ) is curved in two mutually perpendicular directions, wherein the solar cells ( 18A . 18B . 18C ) Pressure applying surface of the die ( 24 ) is formed in the section along both curvature directions as a the respective curvature of the body element replicating traverse. Verfahren gemäß einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass es sich bei dem Karosserieelement um eine gewölbte, mindestens teilweise transparente Scheibe (10) aus Glas oder Kunststoff handelt.Method according to one of the preceding claims, characterized in that it is in the body member is a curved, at least partially transparent disc ( 10 ) made of glass or plastic. Verfahren gemäß einem der vorhergehenden Ansprüche, dadurch gekennzeichnet, dass es sich bei dem Karosserieelement (10) um mindestens einen Teil des Fahrzeugdaches handelt.Method according to one of the preceding claims, characterized in that it is in the body element ( 10 ) at least ei NEN part of the vehicle roof acts.
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