DE102007022964A1 - Method for production of construction unit with solar generator function, involves arranging flexible solar module in forming tool and plastic material is extruded behind and is completely laminar - Google Patents

Abstract

The method involves arranging a flexible solar module (12) in a forming tool and a plastic material (14) is extruded behind and is completely laminar. The solar module is arranged with a front side on a form surface of the forming tool. A separate spraying process plastic material is formed at the front side of the solar module. A polycarbonate material is used as plastic material. An independent claim is also included for a construction unit with a solar generator function.

Description

The The present invention relates to a component, in particular a plate-shaped Component, with solar generator function and a method of manufacture such a component.

Such a component and its manufacture are for example from DE 41 05 389 C1 known. This publication describes a translucent disc for vehicles, in particular a sunroof cover with a translucent outer layer and a flat applied to the inside of this outer layer solar composite. The outer layer is made of glass, acrylic resin, polycarbonate resin or the like. According to one embodiment, the solar composite includes a transparent lower adhesive film, against the underside of which a transparent inner layer rests, which may be made of the same material as the outer layer.

adversely is in this state of the art, especially the effort to manufacture of the component. In addition, the known method is conditional by the solar cells used, only for moderate curved components suitable.

It An object of the present invention is a component, in particular a plate-shaped component, with solar generator function to provide, which can be easily produced and less Restrictions on the design is subject.

These Task is according to the invention by a method according to claim 1 or a component according to claim 5. The dependent claims relate to advantageous Further developments of the invention.

The method according to the invention is characterized that a flexible solar module arranged in a mold and essentially full surface with a plastic material is injected behind.

The term "flexible solar module" is intended to denote any generally flexible arrangement of one or more solar cells connected together electrically. In a preferred embodiment, the flexible solar module is formed by a flexible solar foil containing one or more flexible solar cells. For this purpose, suitable flexible solar cells as such, for example, from US 2005/0074915 A1 known. The flexibility of this known solar cell is to a certain extent a by-product of the development of a solar cell which is as light and space-saving as required, in particular, for satellites and spacecraft.

By the substantially full-surface injection molding of the solar module With a plastic material can advantageously be a shaping for the component, the integration of the solar module and the mechanical Stabilization of the resulting composite in a single operation (Injection process) to be accomplished.

Of the The term "injection molding" is very broad in the context of the invention understand and should be next to an injection process in the strict sense as well include other processes known for molding plastics material, in particular z. B. foaming and the so-called RIM process ("Reaction Injection Molding" process).

The inventive method is particularly suitable for the production of vehicle components, in particular of external components for a motor vehicle. Another preferred use of the inventive method or of the thus produced Component results for two-wheelers, in particular Bicycles (preferably without auxiliary engine). When used as an external component for a motor vehicle is in particular the use of the component in the roof area interesting. At a bicycle In contrast, the use of the component as a front and / or rear "fender" therefore particularly interesting because this Bicycle components often with electrically operated lighting devices are to be provided and the integration and / or operation (power supply) these components can be simplified by the invention. Specific preferred embodiments and embodiments such components will be described in more detail below.

In A preferred embodiment provides that the solar module with its front on a molding surface of the mold is arranged. In this case results in a Component in which a flat side of the (light-sensitive) front of the solar module is formed. That at the back of the Solar module molded plastic material can in this case too be provided opaque, without the solar generator function of the solar module.

The term "injection molding" within the meaning of the invention is also to be understood in a very broad sense, as it should by no means be ruled out that plastic material is also formed (in addition to the back) on the front side of the solar module. In one embodiment, it is accordingly provided that in the same or a subsequent separate injection molding plastic material is formed on the front of the solar module. The molding in a subsequent separate injection process is hereby usually preferred for the following reasons: If, in a first injection process, the Solar module rests with its front on a mold surface of a mold, so it can be advantageously defined a desired deflection or curvature of the flexible solar module by the mold surface, against which the solar module is pressed. In a subsequent separate injection process, in the same or a different mold, further plastic material (the same or another type) can then be applied to the front of the already advantageously fixed in its form solar module, the shaping of the latter plastic material in turn advantageously through the molding surface of the used Mold can be done as desired. The plastic material that is preferably molded onto the entire surface of the front side of the solar module substantially must, of course, be suitably chosen with regard to its transparency taking into account the solar generator function.

In an embodiment is provided that as a plastic material a polycarbonate material (eg polycarbonate or polycarbonate blend) is used. Such a material can be both on the back and (optionally) formed on the front of the solar module become.

The Component according to the invention is characterized that it comprises a flexible solar module, which essentially full-surface with a plastic material behind injected is.

The in particular using one or more of the above already produced specifics of the manufacturing process Component is particularly suitable for use as a component for a motor vehicle, for example as a body component, Roof part (fixed or movable, such as sliding roof cover) or Glazing component.

In an embodiment, it is provided that the component is totally transparent, d. H. a certain perusal allowed. This requires a corresponding transparency of both the solar module as also the plastic material on the front and optionally Back. One for many applications sufficient transparency of the plastic or plastic materials in a simple way z. By the use of a polycarbonate material to ensure. What a sufficient transparency of the solar module As far as can be in a relatively efficient solar module with in the visible spectral range of relatively high absorption be provided that the absorbent solar cell material with provided a plurality of small recesses or holes is that make the solar panel sufficiently transparent.

The Use of the invention is particularly advantageous in practice, if at least one of the flat sides and / or the component as a whole is curved. Due to the flexibility of the solar module can the curvature of the back-injected with plastic material Solar module in the desired manner to the above Curvatures are adjusted.

at a use of the component in the roof area of a motor vehicle can with the invention advantageously taken into account the circumstance be that the roof contour of modern vehicles often a significant curvature in the vehicle longitudinal direction and / or in the vehicle transverse direction.

The according to the invention in a simple manner to be accomplished Curvature of the component is z. B. then very advantageous, if the component has a front or rear "two-wheeler fender" (= Protective cover on a wheel of a two-wheeler) should form.

If the component is provided as a component for a vehicle, so it can be beneficial for the electrical supply of electrical Consumers of the vehicle serve, for example, for supply an electric fan in a parked vehicle, or also for charging or recharging an accumulator such as a Vehicle battery. For example, in a bicycle, the solar generator function of the component for the supply of electrically operated "bicycle accessories" (eg cycle computer with km-counter, clock, etc.) Horn, etc.), including a lighting device (front Headlight and / or taillight) serve. Also for the application in a two-wheeler, especially bicycle with or without Auxiliary motor, the component for charging or recharging a battery be used.

In a preferred embodiment, it is provided that at least one of the solar module can be powered electrical consumers in the plastic material of the component is embedded (partially or completely). If the component z. B. as Dachpaneel (fixed or movable) of a motor vehicle is provided, the embedded electrical consumer z. B. a heater, a lighting device or an antenna amplifier. In the case of an antenna amplifier, it makes sense to embed the associated antenna also in the plastic material. If the component z. B. is provided as a fender on a bicycle, the embedded electrical consumer z. B. a corresponding light unit (front headlight or rear tail light). Also, an energy storage such as an electric accumulator can be embedded in the plastic material of the component. Regardless of the vehicle type is in an off leadership form provided that in the plastic material, an electronic circuit arrangement is embedded, which controls or regulates a charging current for charging an energy storage with the generated solar power. The energy storage in question may, but need not be embedded together with the electronic circuitry in the plastic material of the component.

alternative or additionally, additional electrical or electronic components embedded in the plastic material of the component be, in particular z. B. Line connections (eg between several Solar cells or between a solar cell array and an associated Control electronics).

The Invention will be described below with reference to embodiments with reference to the accompanying drawings explained. They each represent schematically:

1 a sectional view for illustrating the production of a vehicle roof panel with solar generator function,

2 a sectional view of the finished roof panel,

3 a roof panel according to a modified embodiment,

4 a roof panel according to another embodiment,

5 a roof panel according to another embodiment,

6 a top view of a roof panel according to another embodiment,

7 a side view of a front mudguard, and

8th a side view of a rear bicycle apron.

The 1 and 2 illustrate a first example of the preparation ( 1 ) of a roof panel 10 ( 2 ) for a motor vehicle.

In 1 you recognize a top 1 and a lower part 2 a mold for the production of the panel 10 , For this purpose, initially a flexible solar module 12 with its photosensitive front on a mold surface of the mold 1 . 2 , here a form surface 3 of the tool shell 1 , Arranged and optionally fixed in a known manner (not shown) in the mold cavity. Then it is through an inlet channel 4 of the other tool part (lower part 2 ) embedded a polycarbonate material to the trained as a solar foil flexible solar module 12 with the plastic material to inject.

This injection process results in the 2 shown panel 10 in which the solar module 12 is arranged on that flat side of the panel, which forms in use situation an outer portion of the vehicle roof.

For simplicity of illustration, in practice necessary electrical line arrangements are not shown in the figures. For example, such a line connection of the solar module 12 to a likewise in the plastic material 14 embedded connector or a side rail assembly, the / in use situation for connection of the panel 10 to a vehicle electronics.

at the following description of further embodiments the same reference numbers are used for equivalent components each supplemented by a small letter to distinguish the embodiment. It is essentially only on the differences to the or the already described embodiments and, moreover, hereby expressly to the description of previous embodiments directed.

3 illustrates a modified embodiment. The illustrated roof panel 10a again comprises a composite of a flexible solar module 12a and a molded on the back of the same plastic layer 14a , The production of this composite 12a . 14a can in a simple manner as in the embodiment according to the 1 and 2 be realized.

The panel 10a In contrast to the embodiment described above, however, comprises a further plastic layer 16a at the front of the solar module 12a was formed. In the illustrated embodiment, this has already been prefabricated composite 12a . 14a was placed again in a mold and in another injection process, the front-side plastic layer 16a , For example, again a polycarbonate material, molded.

By such a "two-stage" manufacturing process can advantageously the shapes of the two flat sides of the panel 10a as well as the solar module 12a in each case desired, so be realized independently.

4 illustrates an embodiment play a panel 10b the production of which is essentially the production of the panel described above 10a equivalent.

In contrast, in the manufacture of the panel 10b however, in the first injection process (molding of a plastic layer 14b ) an electronic assembly 18b in the plastic layer 14b formed. This electronics 18b is via (not shown) line connections to the solar module 12b connected and performs control tasks in connection with use of the solar generator function for charging a vehicle battery. In addition, in the field of electronics 18b an electrical connection for connecting the panel 10b provided in its use situation. Finally, in the field of electronics 18b also an antenna amplifier for an electrically connected antenna 20b included in the illustrated embodiment in the second injection process in the front-side plastic layer 16b was formed.

5 illustrates an embodiment of a roof panel 10c , its manufacture and construction substantially as in the panel described above 10b are provided.

In contrast to this is an electronic assembly 18c however, in the plastic layer on the outside 16c formed. In addition, the in-use situation becomes outside of the panel 10c serving flat side of a heating foil 22c educated. In the production of the panel 10c was this heating foil 22c placed on the corresponding mold surface of the mold used in the second injection process.

6 shows another, provided as a sunroof cover roof panel 10d in plan view. The overall approximately rectangular panel 10d again has a solar module embedded in the plastic material 12d and an electronic assembly 18d , In addition, as a heater in the upper-side plastic layer 16d an arrangement of heating wires 24d embedded, which is electrically connected to the assembly 18d is connected and, if necessary, depending on the sunlight from the solar panel 12d and / or the electrical system of the vehicle in question, is supplied.

The 7 and 8th illustrate the use of components with solar generator function as bicycle fenders.

7 shows a front bicycle apron 10e comprising a plastic material 14e , which forms a fender body, and a solar module 12e , which in the illustrated use situation a large part of the upper (the wheel facing away) side of the mudguard 10e occupies.

In the production of the mudguard 10e became the solar module 12e arranged in a mold and completely with the plastic material 14e back-injected, as has already been described in detail above for the other embodiments.

The main difference to the embodiments described above is on the one hand in the design (due to the application) and on the other hand in the integration of a front lighting unit 30e , The fender 10e Like the embodiments described above, it can be considered as a plate-shaped component, but with relatively strong curvatures in two directions (following the respective wheel peripheral section in a curved manner and curved in the transverse direction of the tire cross-section on its upper side).

In 7 dashed lines are usually provided for an apron of this type fastening or stabilizing struts.

At least one housing body of the front lighting unit 30e (preferably, for example, LED unit) is integrally made of the plastic material 14e formed, in the illustrated embodiment as a in the front region of the mudguard 10e upward approach. In the area of this housing is also an energy storage 32e provided for storing the solar energy, which is formed in the illustrated embodiment of an electric accumulator with associated charge current control.

The illustrated fender 10e is made of a plastic material such. B. made of polycarbonate or a similar material and already has the injected solar unit 12e , the light unit 30e as well as the energy storage 32e and, moreover, all the necessary electrical wiring ("wiring"). Through this integration of the above components, these are more or less insensitive to external interference such. B. weather conditions (rain, slush etc.) as well as mechanical shock or damage. Unlike conventional bicycle lighting elements, there is no susceptibility to damage or loosening of line connections during operation or in unfavorable weather conditions (eg with dynamo operation in rainy or snowy weather). By integrating the energy storage 32e in connection with the solar module 12e As a rule, a complicated charging or reloading by the user can be omitted.

The beam angle of the front light unit 30e Can be fixed by the corresponding integration on the fender, so that no bending or bending of the light unit as in conventional bicycle lights is possible. Alternatively, it is of course conceivable, even for the illustrated solar fender 10e to provide an adjustability of the radiation angle.

Advantageously, the fender 10e With appropriate design (eg made of polycarbonate) elastic, unbreakable and made with low weight. By integrating the lighting unit 30e There are no electrical contact problems. In addition, no additional attachments (dynamo, screws, cables, etc.) and in particular no parts to be lost are needed for mounting and wiring and power supply. The advantageous already integrated accumulator can be charged in the simplest way by the solar application. In practice, the lighting is therefore always "ready for use", is not subject to the effects of the weather and does not have to be retrofitted. Such a solar fender such. B. the illustrated front fender 10e Of course, however, it can be manufactured and sold as a retrofittable unit.

8th shows a similarly designed rear bicycle apron 10f with a flexible solar module embedded therein 12f , As in the embodiment described above is again an energy storage 32f and a light unit, here rear light unit 34f already in the plastic body 14f integrated.

Another special feature of the illustrated rear mudguard 10f is that a porter part 36f at the top of the mudguard 10f is integrally formed (as well as a housing of the rear lighting unit 34f ).

For the rear fender 10f In particular, the same advantages arise as these already for a front fender of in 7 described type have been described.

Both for a front fender and for a rear fender (see, for example, the 7 and 8th ), an electrical connection device (eg, socket, connector, etc.) may be provided, for example, for the purpose of guiding the generated solar power into another area of the respective bicycle (eg, if an accumulator is not integrated with the relevant fender), or z. B. to create a way to recharge an integrated energy storage independent of the solar power generation, or to be able to connect a separate from the fender control unit (on / off switch, etc.).

In summary is with the embodiments described above the Invention each a polycarbonate element with integrated solar function provided, which in particular for automotive applications and two-wheeler applications is interesting. The described manufacturing method allows advantageous integration of the solar function also for more curved components or component surfaces. In the method, in particular the use of a highly flexible Solar film may be provided by a back injection process in virtually any customizable polycarbonate structures integrated can be. The introduction of the flexible solar module or the Solar film is advantageous during the spraying of the Component material, so no additional application costs arises. It is a large-scale representation the solar surface possible.

Furthermore the method according to the invention is compatible with the desire for an additional integration of electrical or electronic applications, in particular those which use the generated solar power. Conceivable here are in particular Lighting elements, heating elements or antennas (amplifier) elements.

1

top

2

lower part

3

form surface

4

inlet channel

10

roof panel

12

flexible solar module

14

Plastic material

16

Plastic material

18

electronic module

20

antenna

22

heating film

24

heating wires

30

front light unit

32

energy storage

34

rear light unit

36

Carrier part

QUOTES INCLUDE IN THE DESCRIPTION

This list The documents listed by the applicant have been automated generated and is solely for better information recorded by the reader. The list is not part of the German Patent or utility model application. The DPMA takes over no liability for any errors or omissions.

Cited patent literature

• - DE 4105389 C1 [0002]
• US 2005/0074915 A1 [0007]

Claims (9)

Method for producing a component ( 10 ) with solar generator function, characterized in that a flexible solar module ( 12 ) in a mold ( 1 . 2 ) and substantially over the entire surface with a plastic material ( 14 ) is back-injected. Method according to claim 1, wherein the solar module ( 12 ) with its front side on a molding surface ( 3 ) of the molding tool ( 1 . 2 ) is arranged. Method according to one of the preceding claims, wherein in the same or a subsequent separate injection molding plastic material ( 16 ) on the front of the solar module ( 12 ) is formed. Method according to one of the preceding claims, wherein as plastic material ( 14 . 16 ) a polycarbonate material is used. Component with solar generator function, characterized in that the component ( 10 ) a flexible solar module ( 12 ), which essentially covers the entire surface of a plastic material ( 14 ) is injected behind. Component according to claim 5 for use as a component for a motor vehicle. Component according to claim 5 for use as a component for a bicycle, especially for a bicycle, in particular as an apron for a bicycle. Component according to Claim 5 or 6, in which at least one of the flat sides and / or the component ( 10 ) is curved overall. Component according to one of claims 5 to 7, wherein at least one of the solar module ( 12 ) supplyable electrical consumers ( 18 . 22 . 24 ) is embedded in the plastic material of the component.