DE102018213627B4 - Flat material with a photovoltaic module, product with such a flat material and method for producing a flat material - Google Patents

Abstract

Flat material (2), which has three layers (4, 6, 8), namely an outer layer (4), an inner layer (8) and a core layer (6), - the core layer (6) between the outer layer (4) and of the inner layer (8),- the core layer (6) having an organic photovoltaic module (10) which is connected to the outer layer (4) and the inner layer (8),- the inner layer (8) and the outer layer (4) together completely enclose the photovoltaic module (10) and overlap it in an overlapping area (14) so that the photovoltaic module (10) is covered, - the outer layer (4) being transparent at least in the overlapping area (10) in such a way that this allows light (L) to pass through to the photovoltaic module (10) for generating energy,- at least in the overlapping area (14) the outer layer (4) being designed in such a way that it has a textile or leather-like feel,- the outer layer (4 ) a surface structure turing (16) has to form the textile or leather-like feel.

Description

The invention relates to a flat material with a photovoltaic module, a product with such a flat material and a method for producing a flat material.

Mobile end devices have an important place in everyday life these days and it is hard to imagine many applications and human communication without them. For example, there are around 1.4 billion smartphones in the world alone - and the trend is rising. A widespread problem with these mobile devices is the limited battery life when used frequently or when using power-consuming applications, such as gaming apps. Fixed devices, such as sockets on trains or charging stations in shopping centers or airports, can help, but these devices have the disadvantage that they are in a fixed place and therefore only for a limited time, for example the duration of the journey or the time in the shopping center , Are available.

Possible mobile products for charging the batteries of mobile end devices are so-called power banks, i.e. energy storage chargers with which the batteries of mobile end devices can also be charged on the go. The problem with this, however, is that power banks can often only store energy for a few battery charges and then have to be recharged themselves. Power banks are also comparatively unwieldy and can heat up uncomfortably during operation.

Other possible mobile products for charging batteries are solar chargers or solar power banks, which generate the electrical energy required to charge the batteries of mobile devices from sunlight. Such products are ecologically beneficial through the use of solar energy. At the same time, it is important for many users to know where the electrical energy comes from, in contrast to the electrical energy from the socket. The problem, however, is that these solar cell-based chargers or power banks have to have comparatively large areas for the solar cells so that sufficient energy is produced to charge the batteries or the power bank itself can be charged in a comparatively short time. In addition, solar chargers or solar power banks must have contact with sunlight in order to fulfill their charging or charging function, i.e. charging or charging cannot take place when these products are transported in bags or the like.

There is therefore a need for a product that offers a comprehensive solution and eliminates the problems of the known mobile chargers. In addition, design aspects must also be taken into account for products for charging rechargeable batteries, in particular in order to achieve the highest possible level of acceptance when using such products in everyday life.

An embedding of solar cells between two protective layers is described in U.S. 8,933,524 B2 , U.S. 8,835,519 B2 and U.S. 8,101,684 B2

In the U.S. 9,724,869 B2 describes a multi-layer structure for an electronic device, such as a bracelet or a portable computer. Electronic components are arranged on a flexible substrate of the multilayer structure.

Against this background, it is an object of the invention to enable mobile charging and to make it as convenient and reliable as possible. A charging function that is as convenient and reliable as possible should therefore be provided, in particular for charging a mobile terminal device. Design aspects should also be taken into account.

The object is achieved by a flat material with the features according to claim 1, by a product with the features according to claim 12 and by a method with the features according to claim 15. Advantageous refinements, developments and variants are the subject of the dependent claims. The explanations in connection with the surface material also apply to the product and the process and vice versa.

The planar material is in particular a planar material, i.e. a material which generally extends in any two dimensions and has a comparatively small overall layer thickness. The flat material is particularly flexible and can therefore be processed particularly well. In a suitable configuration, the flat material can be produced and manufactured as a continuous product; in a suitable variant, the flat material is prefabricated and then has correspondingly specific dimensions, which are adapted to a specific intended use. Overall, the planar material is preferably designed in the manner of a textile and can advantageously also be processed like such.

The sheet material has three layers, namely an outer layer, an inner layer and a core layer. In this respect, the planar material is composed of several layers overall. The surface material is therefore also referred to as "layered composite" or "layered material". The outer layer, the inner layer and the core layer are each also referred to generically as a layer. The outer layer is also referred to as the "outer layer" or the "outside". The inner layer is also referred to as the "inner layer" or the "inside".

The core layer is positioned between the outer layer and the inner layer. The core layer has an organic photovoltaic module which is connected to the outer layer and the inner layer, respectively. The photovoltaic module is also referred to as a "PV module" or as a "photovoltaic element". The photovoltaic module serves to generate energy by absorbing light that penetrates the surface material and the photovoltaic module from the outside. The photovoltaic element is used to generate solar energy, preferably for the purpose of charging a battery, in particular a mobile terminal device. The arrangement of the photovoltaic module between two further layers is based in particular on the idea that the layer structure of the flat material advantageously enables the use of photovoltaic modules within a material to be processed constructively, with various products with the most varied shapes then being produced from this material, namely the flat material let and preferably also be produced. The special flat material has the advantage that the photovoltaic module in the flat material is protected from external influences, such as weather or other potentially damaging influences, but at the same time is also visually and haptically hidden and the overall optical and haptic impression of the product made from the flat material and its design are not affected. The resulting product is preferably a three-dimensional body that can be deformed in a certain way, e.g. stretched and compressed, in particular due to the flexibility of the sheet material, without damaging the photovoltaic module.

In the present case, the photovoltaic module is an organic photovoltaic module and is therefore particularly flexible, so that the flexibility of the surface material as a whole is advantageously not influenced by the photovoltaic module. The presence of the photovoltaic module therefore advantageously leads to no or at least no significant restrictions with regard to the usability and processability of the planar material. The photovoltaic module is connected to the inner layer and the outer layer in each case and is thereby in particular fixed in its relative position with respect to these two layers.

The photovoltaic module has one or more photovoltaic elements, which in turn each have one or more cells. A cell represents in particular the smallest electrical unit of the photovoltaic module. In the case of multiple cells or multiple photovoltaic elements, these are suitably electrically connected to one another in order to achieve a specific voltage or a specific current, for example.

The core layer is preferably only formed by the photovoltaic module, i.e. the core layer has no other components, so that the terms "core layer" and "photovoltaic module" refer to the same object.

The inner layer and the outer layer together completely enclose the photovoltaic module and overlap with the photovoltaic module in an overlap area such that the photovoltaic module is covered. The photovoltaic module generally has a front surface through which light is absorbed for power generation and an opposite back surface. The front is then oriented and bonded to the outer layer while the back is oriented and bonded to the inner layer. As a result, the photovoltaic module is completely enclosed by the inner layer and the outer layer and covered on both sides.

In order to generate energy, the outer layer is transparent, at least in the overlapping area, in such a way that the outer layer lets light through to the photovoltaic module. The outer layer is therefore translucent at least in the overlapping area. The outer layer preferably has a transparency in the range from 80% to 100%. The transparency is set in particular by a suitable choice of material.

Preferably the outer layer is transparent to sunlight. In an expedient configuration, however, the outer layer is only transparent for a part of the spectrum of sunlight, so that the outer layer appears correspondingly colored. Although this reduces the amount of light that reaches the photovoltaic module, it achieves a coloring of the surface material that is advantageous from a design point of view. Also conceivable and suitable is an embodiment in which the outer layer is transparent only in a non-visible spectral range, so that a maximum degree of freedom is achieved with regard to the color scheme of the outer layer. For example, only infrared and/or UV radiation is allowed to pass through the outer layer.

In addition, the outer layer is designed in the overlap area in such a way that it has a textile or has a leather-like feel. This means in particular that the outer layer has a textile or leather-like feel to the touch, ie has or imitates the feel of a textile, eg a fabric, or leather and generally a textile or non-textile sheet material.

The special transparency and feel of the outer layer are formed at least in the overlapping area as described above, but the outer layer is preferably formed homogeneously overall in such a way that the outer layer has the same haptic and preferably also the same optical properties over its entire surface. The outer layer is therefore not segmented into different zones with different properties, but is of the same design throughout.

A core idea of the invention consists in particular in integrating a photovoltaic module into the textile-like sheet material in such a way that the photovoltaic module fits into the sheet material as unobtrusively as possible, i.e. it is not visible and cannot be felt by an observer, especially from the outside. In the present case, this is realized by the special outer layer. Because the outer layer is transparent, the technical functionality of the surface material is guaranteed, namely the generation of energy. On the other hand, due to the special feel, the surface material feels like a textile or leather. By covering the photovoltaic module with the outer layer, a particularly homogeneous visual impression is also achieved on the outside, as a result of which the photovoltaic module also recedes optically into the background. This also applies correspondingly to the inner layer, which covers the rear of the photovoltaic module.

As a result of the photovoltaic module being enclosed between the inner layer and the outer layer, the photovoltaic module is initially advantageously optimally protected from the weather or other damage and impairments, but is also preferably not palpable. The photovoltaic module thus disappears visually as well as haptically as far as possible or even completely within the surface material. This is particularly advantageous from a design point of view, since a technical functionality is now realized which has a particularly small influence on the design of the surface material and on a product made from it. This means that surface materials and products can be produced that are equipped with a corresponding technical functionality, here energy generation, and largely independently of this have an advantageous appearance, which in particular leads to increased acceptance of everyday use. At the same time, a particularly attractive design of a product is realized by the outer layer and the inner layer, preferably a particularly homogeneous appearance in terms of color and structure. In general, the optics, i.e. shape and color, of the photovoltaic module and the outer layer as well as the haptics of the entire surface material are therefore preferably selected and adjusted under design aspects and advantageously also coordinated with one another and a technical functionality is additionally, but preferably subordinately, implemented.

The sheet material has a total layer thickness which is preferably at least 1 mm and at most 5 mm. As a result of this and the special layer structure, it is advantageously achieved that the surface material resembles a textile or leather, for example belt leather, in terms of its feel, its bending and shape behavior and its durability.

The outer layer represents an outermost layer within the sheet material, which is typically in direct contact with the environment, in particular with sunlight or another light source. In terms of design, this outer layer is in particular the most important layer, since it creates the visual and haptic point of contact with the product and its design for a user.

In the present case, the outer layer has a surface structure, in particular an embossing, to form the textile or leather-like feel. The outer layer is so structured on the outside to at a

Touch to produce a defined feeling of touch, namely the impression that the surface material is at least a textile or leather on the outside. The haptics of the planar material or a product made from it are adjusted by forming the surface structure. The surface structure is preferably formed over the entire outer layer. In a first configuration, the surface structuring is of the same design everywhere on the entire outer layer; in one variant, the surface structuring varies depending on the position on the outer layer, so that a locally varying feel is realized.

During the manufacture of the planar material or alternatively during the manufacture of a product from it, the surface structure is produced by embossing, laser texturing, or another structure-giving machining or manufacturing process. The outer layer is particularly structured three-dimensionally, ie the upper surface structuring forms a tactile, relief-like structure, for example a wave-like structure, and generally a structure consisting of elevations and depressions. The elevations and depressions are, for example, each pointed or rounded, or a combination thereof.

The surface structuring not only improves the haptic properties of the planar material, but preferably also one or more optical properties. In an expedient embodiment, the surface structuring is designed in such a way that it directs incident light to the photovoltaic module in a targeted manner or even focuses it on it, e.g. through a prism effect or a lens effect, which in particular improves the generation of energy. Alternatively or additionally, the surface structuring is formed as an antireflection structuring, ie as a structure by which the reflectivity of the outer layer is reduced.

In an expedient embodiment, the photovoltaic module has a circuit layout with a dead zone in which no light absorption and thus no energy generation are possible. A busbar or an electrode, for example, is arranged in the dead area, which in particular covers an underlying active material. The surface structuring is then expediently designed in such a way that light is guided away from the dead area and towards an active area. In contrast to the dead area, the active area is not covered, so that light that reaches the active area from the outer layer is absorbed to generate energy.

The outer layer preferably has a layer thickness in the range from 0.2 mm to 3.0 mm. The outer layer is generally expediently made of a plastic. In a preferred embodiment, the outer layer consists of a TPU, i.e. a thermoplastic polyurethane, or of a silicone. These materials are characterized by good workability and, in particular, good modeling properties, as well as good durability and flexibility. In addition, the feel of the surface material can be adjusted particularly well with these materials. Both materials have a high degree of design freedom. If a silicone is used, it is preferably processed in the liquid phase during manufacture.

The inner layer preferably has a layer thickness in the range from 0.2 mm to 3.0 mm. In a product made from the sheet material, the inner layer faces inwards and is thus arranged on an inside of the product. First of all, there are no special requirements for the inner layer, particularly with regard to the permeability of light. In particular, the inner layer preferably serves to stabilize the planar material or to color the planar material, or both.

In a preferred embodiment, the inner layer is opaque, i.e. in particular non-transparent or opaque, so that the photovoltaic module is not visible through the inner layer. The presence of the photovoltaic module and, in general, of the core layer is thus advantageously optically disguised. The photovoltaic module is therefore invisible to a user and preferably cannot be felt either.

At the same time, the inner layer is expediently designed to be visually and haptically appealing, particularly in the case of products where a user can see or feel the inside of the product, such as bags and suitcases. In a preferred embodiment, the inner layer therefore consists of a textile, especially in particular a fabric, or leather. In general, the inner layer preferably consists of a material with a fabric or leather-like feel. In a suitable embodiment, the inner layer is a fabric layer, i.e. a layer of fabric woven from natural or man-made fibres.

In a preferred embodiment, the outer layer has a pattern that is visible from the outside, and the photovoltaic module has a circuit layout that is designed in such a way that it visually corresponds to the pattern of the outer layer. This is based in particular on the consideration that the photovoltaic module may still be visible to a certain extent from the outside due to the transparency of the outer layer and possibly despite a surface structure. In order to further disguise the photovoltaic module, its visual appearance is therefore adapted as far as possible to the visual appearance of the outer layer. This is particularly possible with an organic photovoltaic module, since such a module has a particularly high degree of design freedom with regard to its circuit layout. The circuit layout and especially its visual appearance are primarily defined by the individual cells of the photovoltaic module and how they are connected to one another. The overall appearance of the photovoltaic module is then adapted to the outer layer by appropriate arrangement of the cells relative to one another and by appropriate design of electrodes and connections. However, alternative or additional is also suitable Lich a reverse procedure, in which the outer layer is specifically provided with a pattern that imitates or absorbs the optical appearance of the photovoltaic module.

In a preferred configuration, a first intermediate layer is arranged between the photovoltaic module and the outer layer and a second intermediate layer is arranged between the photovoltaic module and the inner layer. The first intermediate layer and the second intermediate layer are each formed as an adhesive layer and thereby connect the photovoltaic module to the inner layer and the outer layer in a materially bonded manner. The use of two intermediate layers at the same time is not absolutely necessary per se, but is preferred. An embodiment in which only one intermediate layer is used either between the photovoltaic element and the outer layer or between the photovoltaic element and the inner layer is also fundamentally suitable. The intermediate layers do not necessarily have to be of the same design, but can also differ, in particular with regard to the choice of material and dimensioning.

The additional intermediate layers achieve a particularly strong connection between the photovoltaic module and the surrounding layers. The intermediate layers serve here in particular as adhesion promoters. The respective intermediate layer advantageously improves lamination or welding of the core layer to the inner layer or the outer layer during production of the planar material. This is particularly advantageous in connection with the inner layer if this consists of a textile or leather as described above.

In general, the intermediate layers preferably each consist of a plastic. In a particularly expedient embodiment, the intermediate layers each consist of a TPU or a silicone. The same material is expediently selected for both intermediate layers; alternatively, the intermediate layers are made of different materials. The first intermediate layer preferably consists of the same or a similar material as the outer layer. The second intermediate layer preferably consists of the same or a similar material as the inner layer. In this way, in particular, an optimum bond is achieved in each case. The intermediate layers each have a layer thickness preferably in the range from 0.2 mm to 3.0 mm.

The photovoltaic module itself has a layered structure and has an active layer for absorbing light and generating energy. For this purpose, the active layer has an organic semiconductor material or an organic semiconductor material composite. This material results in particular in the special and, in comparison to crystalline materials, greater flexibility of the photovoltaic module. In particular, the active layer is enclosed by two electrodes, namely a top electrode and a bottom electrode. The energy generated can be dissipated via the electrodes and fed to a consumer. The photovoltaic module is preferably produced by a printing process and expediently as a freely configurable endless film, which can advantageously be produced with the desired dimensions depending on the design of the sheet material or the product. In general, rigid materials, in particular crystalline semiconductor materials as the active layer or glass as the substrate or for encapsulation, are dispensed with in the organic photovoltaic module in order to achieve the highest possible flexibility. Instead, a plastic is preferably used as the substrate, particularly preferably PET.

In a preferred embodiment, the photovoltaic module has two barrier layers on the outside and is encapsulated by them. Accordingly, the barrier layers form two outermost layers of the photovoltaic module and protect the inner layers, in particular the active layer and the electrodes, from environmental influences. A further advantage is that the photovoltaic module can be integrated non-destructively into the surface material and connected to the other layers. In addition, the barrier layers also have a mechanically stabilizing and protective effect.

The barrier layers are preferably made of PET. In a preferred embodiment, the two barrier layers are each formed as a PET film. In a suitable configuration, the barrier layers additionally have a vapor coating, e.g. made of metal or silicon oxide, particularly on the outside.

In a preferred embodiment, the core layer only extends over a portion of the planar material, so that the outer layer is connected directly to the inner layer outside of this portion. “Directly connected” is understood to mean in particular that the outer layer is connected to the inner layer directly or at most via the above-mentioned intermediate layers and that no further layers are otherwise arranged between the outer layer and the inner layer. This is based on the consideration that it is basically sufficient for the core layer to be present at least partially in the planar material, ie the core layer does not have to extend over the entire planar material, but is then only in one or in several areas of the planar material that are in particular independent of one another. The dimensions of this area or of the several areas depend in particular on the expected incidence of light and thus in particular on the expected usage behavior and the specific design of the product. For example, it would not be expedient for the core layer with the photovoltaic module to also be present in the surface material at those points on a product where additional applications are arranged, for example small pockets, since no light could penetrate to the photovoltaic module at these points. Correspondingly, no photovoltaic module is preferably arranged in those areas of the planar material to which an additional application is attached or is intended for later attachment, ie these areas are free of a photovoltaic module.

When extending only over a partial area of the sheet material, an edge area is preferably formed, which completely and without interruption surrounds the core layer and specifically the photovoltaic module, so that the photovoltaic module is completely embedded and encapsulated between the outer layer and the inner layer. The inner layer and the outer layer are then connected directly to one another, particularly in this edge area.

Especially in an embodiment in which the core layer does not extend over the entire sheet material, but is only present in one or more regions as described above, the core layer is preferably encapsulated by the outer layer and the inner layer. For this purpose, the outer layer and the inner layer are connected directly to one another in the areas without a core layer or, specifically, preferably laminated to one another.

Also suitable is an embodiment in which the core layer extends almost over the entire area of the planar material, i.e. in particular over at least 95% of the total area of the planar material. In other words: the core layer is only encapsulated by the other layers via correspondingly narrow edge areas, e.g. the edge area has an edge width in the range from 0.5 mm to 10 mm. This also applies analogously to a product that is made from the flat material and in which, for example, seams or appliqués or the like are then accommodated in a corresponding edge area.

A configuration in which at least one and preferably several properties of the surface material is or are homogeneous over its entire surface is particularly expedient. Alternatively, at least the outer layer is designed in this way. Despite a photovoltaic module that is only arranged locally, the surface material behaves the same at every point with regard to this property, regardless of whether a photovoltaic module is arranged at this point or not. As a result, the presence of the photovoltaic module is disguised particularly effectively. The planar material or at least the outer layer is particularly preferably homogeneous with regard to one or more of the following properties: layer thickness, transparency, color, structure, pattern, bending flexibility, rigidity. This advantageously creates an overall particularly homogeneous impression of the planar material and correspondingly also of a product made from it.

A product according to the invention is at least partially made from the flat material and has a charging connection, which is connected to the photovoltaic module, for charging a mobile end device using the photovoltaic module. In this respect, the object is also achieved in particular by using a planar material as described above in a corresponding product or for production. In a suitable embodiment, the charging connection is a USB connection. In general, the charging connection is expediently designed so that any possible charging cable or wireless charger can be connected to it, so that different mobile end devices from different manufacturers can be charged without the use of additional adapters.

First of all, there are no other special requirements for the product itself, other than that the product has a surface which faces generally outwards and towards a light source and which is formed from the sheet material. A sub-area of the product is therefore designed to be advantageous both optically and haptically on the one hand due to the surface material and on the other hand it is also technically functional, especially due to the photovoltaic module.

The product is preferably a mobile product, that is to say it is not stationary but, in principle, transportable. The term mobile product means, in particular, a mobile, also portable, three-dimensional object that can be carried or used outside, i.e. outside closed rooms or buildings. Particularly preferred products are transport and storage containers, especially bags and suitcases; Means of transport, in particular baby carriages; outdoor and camping products, in particular parasols and tents; inflatable boats or boat accessories, in particular sails; Clothing, in particular coats, jackets, protective vests or protective clothing for motorcycles, bicycles or generally being safety clothing; and caps, hats or caps, in particular sun hats, cowboy hats, hiking hats, peaked caps, in particular baseball caps or snapback caps.

In the present case, the following items in particular are counted among the terms bag or suitcase: briefcases and briefcases, including laptop or notebook bags; handbags, for example shoppers, pochettes, weekend bags, baguettes, messengers or clutches; rucksacks, for example carrying frames, packboards, courier rucksacks, laptop or notebook rucksacks, city rucksacks, suitcase rucksacks, photo rucksacks, trekking rucksacks, drinking rucksacks, knapsacks, duffel bags or school rucksacks; traveling bags, including weekend bags or weekenders; school bags or satchels; sports bags; messenger bags or shoulder bags in general, including postman bags; fanny packs; carrier bags; Bags for two-wheelers, in particular tail bags, bicycle or motorcycle bags or cases, saddlebags (including saddlebags that can be used for transport animals such as horses), tank bags; suitcases, in particular trunks and trolleys; bags, for example gym bags; crates and boxes.

In the present case, bags and suitcases are preferred as mobile products. Bags, in particular briefcases, handbags, rucksacks, courier bags or shoulder bags, fanny packs and bags for bicycles are particularly preferred.

In the present case, a mobile terminal device is in particular a portable electronic device which can be operated and/or controlled by a human in some way. Mobile devices are in particular the following devices: mobile phones, in particular smartphones and phablets; tablets; video and photo cameras; mobile players such as MP3 players; notebooks or laptops; e-book readers; portable loudspeakers or boxes; wireless headphones; Portable medical devices, such as long-term ECG devices, measuring devices, for example for measuring insulin levels, mobile oxygen devices; and portable lights such as LED lights or flashlights.

In a preferred embodiment, an energy store, in particular a power bank or a rechargeable battery, is connected to the charging connection of the product. When exposed to light, the energy store is then charged. The mobile terminal device is then connected indirectly to the charging connection via the energy store and charged accordingly via the interposed energy store. This enables the available light to be used particularly efficiently. Irrespective of the state of charge of the mobile end device, the local energy store is charged when there is light, by means of which the mobile end device can then be charged in the event of an acute need, regardless of whether there is light at that time or not.

The intermediate energy store is preferably portable and preferably removable. As a result, the energy store can be removed from the product, preferably when fully charged, so that it can also be used independently of the product for charging electrical devices. In a preferred embodiment, the product has an inner pocket that is independent of the rest of the product and can be removed, in which the energy store is accommodated. This inner pocket is attached to the product via a detachable connection. The detachable connection has in particular buttons, cords, one or more Velcro fasteners, one or more snap fasteners or one or more magnetic fasteners. The material for the inner bag is preferably a soft material. Wool felt, leather, artificial leather or a material made of woven natural or artificial fibers is particularly suitable as the soft material. The inside pocket has a compartment for the energy storage. A cable leads into the compartment from an inside of the product and connects the photovoltaic module to the energy store. The concept of the inside pocket can also be applied to the mobile end device, so that the product then has an inside pocket to hold the end device. The charging connection is then expediently arranged in the inner pocket and is accessible within this in order to connect the terminal device for charging.

In a further preferred embodiment, the mobile product has a control unit, by means of which the photovoltaic module or individual photovoltaic elements can be electrically disconnected. In other words: the control unit is designed to disconnect the photovoltaic module or parts thereof from the electrical circuit. This counteracts the problem of possible shading, especially partial shading of the photovoltaic module. If parts of the photovoltaic module are in the shade, this can lead to extensive yield losses, with the percentage yield loss often being higher than the proportion of the shaded area. Parts of the photovoltaic module are, for example, one or more photovoltaic elements or one or more cells of the photovoltaic module. Those parts of the photovoltaic module that are shaded are also referred to as shaded parts. For complex shaped and esp With special three-dimensional objects such as the products described here, there is a risk that due to the shape of the product alone, one or more parts of that product and thus also the photovoltaic module will be shaded. The control unit now separates the shaded parts of the photovoltaic module from the circuit either automatically or manually. The manual control takes place, for example, by means of a corresponding switch or, for example, software-controlled and carried out by the user, for example using a smartphone app. Also advantageous is a configuration in which one or more sensors are attached to the product, in particular on its outside, which measure the intensity of the incident light and pass it on to the control unit, which then in the event of shading, ie when the intensity of the incident light is low , which automatically switches off the shaded parts, i.e. disconnects them from the circuit.

The product generally has a basic shape, which varies depending on the purpose of the product and which significantly characterizes the appearance of the product. In the case of the product, the planar material is then preferably an element which determines the basic form of the product, in one variant the basic form is additionally determined by a basic framework, i.e. a frame, a skeleton or the like. The surface material thus essentially determines the look and feel and in general the design of the product. The outer layer of the planar material is in particular in direct contact with the environment and thus also with light, specifically with sunlight or another light source. Thanks to the integration of the photovoltaic module in the surface material, the product can be used for its usual purpose and at the same time generates electricity to charge the battery of a mobile device if there is contact with the light.

In the event that the product has several parts of the sheet material, it is conceivable that - depending on the product and its design - certain parts of the sheet material have no core layer, but always at least one of the several parts has a core layer with a photovoltaic module.

In contrast to conventional solar chargers and solar power banks, a product as described above is designed in such a way that electrical energy is also generated during transport itself, especially if the product is a means of transport, e.g. a bag or a suitcase. At the same time, the product advantageously also generates electricity in buildings if the product is placed in a place similar to a solar charger or a solar power bank where there is contact with light.

The integration of the photovoltaic module in the flat material has the further advantage that an additional attachment of a photovoltaic module on the outside of a material from which a product is formed is avoided. The attachment of photovoltaic modules can both reduce the visual impression of the mobile product and, depending on the type of attachment, lead to adhesion problems in that the photovoltaic module detaches and becomes unusable as a result. Another problem is that crystalline photovoltaic modules in particular are comparatively heavy and have to cover a large area in order to achieve sufficient power. In addition, crystalline photovoltaic modules in particular are comparatively rigid and therefore also susceptible to destruction.

In a suitable embodiment, the product has the flat material as a single part, a so-called "one piece unit", i.e. the flat material is designed in one piece and is not broken into several individual parts. Advantageously, the flat material is designed in such a way that it has a particularly high level of stability and forms the sole supporting structure of the product, so that a basic structure is not necessary and such is then preferably dispensed with. In this case, corresponding edge ends and/or corners of a one-piece sheet material are preferably connected to one another and/or to other areas of the sheet material in order to form the basic shape of the product therefrom. For example, the product has the basic shape of a bag or a suitcase. Other products, particularly items of clothing, are formed in a suitable embodiment from a one-piece sheet material without the need for a connection of edge ends and/or corners to one another or to another area. If necessary, a hem is formed here by turning over and sewing an edge.

In a suitable variant, on the other hand, several parts that are initially separate from one another are made of the flat material and then assembled to form the product. In other words, the product has two or more pieces of sheet material, which advantageously allows construction of products with more complex shapes. In this case, in particular, at least two or more pieces of sheet material are joined together to either form the product itself, such as when joining multiple pieces to form a garment, or to form a sheet from which, if necessary, in combination with other materials the product is formed, for example as in the case of a parasol, the sheet material then being attached to an appropriate framework.

A connection of edge ends and/or corners of the flat material, as well as a connection of several parts of the flat material, takes place, for example, by sewing, gluing, riveting, buttons, screwing, lacing, one or more Velcro fasteners, one or more snap fasteners or one or more magnetic fasteners. The photovoltaic module is expediently left out or bypassed, i.e. a connection in the area of the photovoltaic module is expediently avoided in order not to damage the photovoltaic module. A connection is therefore preferably only formed at those points at which no photovoltaic module is arranged. A distance of at least 10 mm, particularly preferably at least 30 mm, is preferably formed between the photovoltaic element and a connection.

In a suitable configuration, the product is formed solely from the flat material and, in an alternative suitable configuration, has a basic structure to which the flat material is attached. For example, like a parasol, a baby carriage or various suitcases, the product has a basic structure, e.g. a frame or a skeleton, to which the sheet material is attached and preferably fastened. For example, the surface material is clamped onto the basic structure. The planar material is attached to the basic structure, for example, via appropriate loops in or on the planar material, or by gluing, riveting, sewing, buttoning, screwing, lacing, one or more Velcro fasteners, one or more snap fasteners or one or more magnetic fasteners. The respective points of the planar material at which this is attached to a basic structure is preferably free of a photovoltaic module. The above statements regarding the connection of a surface material to itself or to other parts apply accordingly. Here, too, there is preferably a distance of at least 10 mm, particularly preferably at least 30 mm, between a connection point for connection to a basic structure and a photovoltaic module.

The basic structure consists e.g. of wood, metal, plastic or combinations thereof. Very light, stable and resilient materials are preferred for the basic structure, in particular composite materials, glass fiber materials, carbon, titanium, aluminum, bamboo, hickory, oak, beech, ash, elm, walnut, cherry or maple. The basic framework is designed either in one piece or in several parts, e.g. composed of several parts which can be or are connected to one another by means of a positive connection, a non-positive connection or a material connection. Preferred forms of connection are gluing, riveting, plugging together, welding, knotting, clamping, screwing, one or more tongue and groove connections, one or more zipper-like connections, one or more dovetail connections, one or more connection fittings or a combination of the aforementioned connection types.

In an advantageous embodiment, the product has further applications, e.g. buttons, additional pockets, drawing rolls or compartments, zippers, eyelets or loops, e.g. for attaching a shoulder strap to bags, removable or fixed (side) elements on the outside and/or inside the surface material, which at the same time define the outside and the inside of the mobile product.

The method according to the invention serves to produce a planar material as described above. The planar material has three layers, namely an outer layer, an inner layer and a core layer, with the core layer being laminated in between the outer layer and the inner layer, with the core layer having a photovoltaic module which is connected to the outer layer and the inner layer, the photovoltaic module covered on both sides in particular by being arranged so that they overlap with the inner layer and the outer layer in an overlapping area and being completely enclosed by the inner layer and the outer layer together, the outer layer being transparent at least in the overlapping area in such a way that it lets light through to the photovoltaic module , for generating energy, wherein at least in the overlapping area the outer layer is designed in such a way or, in a development as part of the method, is designed in such a way that this very outer layer has a textile or leather-like feel.

In the present case, the three layers are laminated together, ie the outer layer, the core layer with the photovoltaic module and the inner layer are stacked on top of one another and pressed together. In this case, a pressure treatment and a temperature treatment take place, so that a lamination takes place as a result. The sheet material is then correspondingly a laminate. During the pressure treatment, the layers are preferably applied together at a pressure in the range of 1 bar pressurized up to 20 bar. During the temperature treatment, the layers are preferably jointly exposed to a temperature in the range from 80.degree. C. to 180.degree.

In a preferred embodiment, the textile or leather-like feel is formed in that a surface structure is embossed into the outer layer. In a first variant, the embossing takes place only after the layers have been assembled to form the planar material, in a second variant, the embossing takes place before the assembly.

In an expedient embodiment, an embossing tool is used for embossing, which tool contains a negative of a surface structure, which is then embossed. However, other embossing methods as described above are fundamentally conceivable and also suitable. In a suitable embodiment, the embossing tool is a structured, e.g. corrugated silicone film, by means of which a surface structure is formed in the outer layer.

With an outer layer made of silicone, in a suitable embodiment, the silicone is applied in liquid form to the embossing tool, solidifies there and takes on the surface structure accordingly. In another suitable embodiment, the outer layer is made of TPU, which is heated and pressed against the embossing tool, so that the outer layer takes on the surface structure.

When producing the planar material, the use of one of the intermediate layers or both intermediate layers as described above is particularly advantageous. The core layer and especially the photovoltaic module are laminated in between the outer layer and the inner layer. For this purpose, the layers and the intermediate layers are initially put together in an overlapping manner, so that the intermediate layers surround the core layer and this is then connected particularly firmly to the outer layer and the inner layer.

• 1 einen Ausschnitt eines Flächenmaterials in einer Draufsicht,
• 2 das Flächenmaterial aus 1 in einer Schnittansicht,
• 3 ein Erzeugnis, welches aus dem Flächenmaterial hergestellt ist,
• 4 das Erzeugnis aus 3 in einer Schnittansicht,
• 5 eine Variante des Flächenabschnitts.

Exemplary embodiments of the invention are explained in more detail below with reference to a drawing. They each show schematically:

• 1 a section of a surface material in a plan view,
• 2 the surface material 1 in a sectional view,
• 3 a product made from the sheet material,
• 4 the product out 3 in a sectional view,
• 5 a variant of the surface section.

the 1 and 2 show a section of a flat material 2. The flat material 2 is a flat material which can generally have any shape as shown in 1 shown extends in two dimensions and has a comparatively small total layer thickness D1. The flat material 2 is flexible and can therefore be easily processed. The flat material is produced here as a continuous product, but in a variant that is not shown it is prefabricated and then has correspondingly specific dimensions which are adapted to a specific application. Overall, the planar material 2 is designed in the manner of a textile and can accordingly also be processed like such.

The sheet material 2 shows how 2 First of all, three layers 4, 6, 8 are clear in principle, namely an outer layer 4, an inner layer 8 and a core layer 6 arranged in between. The core layer 6 has an organic photovoltaic module 10, which is connected to the outer layer 4 and the inner layer 8, respectively and which is present for charging a battery of an in 2 mobile terminal not shown in detail is used. On the one hand, the special surface material 2 protects the photovoltaic module 10 from external influences. At the same time, however, this is also hidden visually and haptically, so that the overall visual and haptic impression and the design of the surface material 2 itself and a product 12 made from it, such as in 3 shown are not affected.

In the present case, the inner layer 8 and the outer layer 4 together completely enclose the photovoltaic module 10 and overlap with it in an overlap region 14, as shown in FIG 1 and 2 can be seen, so that the photovoltaic module 10 is covered overall.

In order to generate energy, the outer layer 4 is transparent at least in the overlapping area 14 in such a way that the outer layer 4 lets light L through to the photovoltaic module 10 . The outer layer 4 is therefore translucent at least in the overlapping area 14 . In addition, in the overlapping area 14 the outer layer 4 is also designed in such a way that it has a textile or leather-like feel and therefore feels textile or leather-like when touched. The special transparency and feel of the outer layer 4 are not necessarily only formed in the overlapping area 14 . In the exemplary embodiment shown, the outer layer 4 is even formed homogeneously overall in such a way that it has the same haptic and optical properties over its entire surface. The photovoltaic module 10 is so in the textile-like Surface material 2 integrated in that the photovoltaic module 10 fits into the surface material 2 as unobtrusively as possible and is not visible to an observer from the outside and cannot be felt. This is realized here by the special outer layer 4, which on the one hand ensures the technical functionality of the surface material 2 and on the other hand hides the photovoltaic module 10 haptically and visually and thus generally contributes to a homogeneous overall impression.

In 3 a product 12 is shown in a perspective view, which is made of the sheet material 2 . The product 12 is a suitcase or bag here. 4 Figure 12 shows the product 12 in a top cross-sectional view. How from the 3 and 4 As becomes clear, the outer layer 4 within the planar material 2 represents an outermost layer, which is typically in direct contact with the environment and thus with a light source. The outer layer 4 is the most important layer in terms of design, since it creates the optical and haptic point of contact with the product 12 and its design for a user.

In the present case, the outer layer 4 is structured on the outside and has a surface structure 16 to form the textile or leather-like feel. As a result, when touched, a defined feeling of touch is generated, namely the impression that the planar material 2 is a textile or leather, at least on the outside. The surface structure 16 is formed over the entire outer layer 4 here. In the present case, the surface structuring 16 not only improves the haptic properties of the planar material 2 , but also the optical properties, in that incident light L is directed onto the photovoltaic module 2 in a targeted manner. The surface structure 16 is particularly in cross section 2 recognizable and for the sake of simplicity in 4 but not explicitly shown.

Alternatively or additionally, the outer layer 4 has a pattern M which is visible from the outside, and the photovoltaic module 10 has a circuit layout S which is designed in such a way that it visually corresponds to the pattern M of the outer layer 4 or vice versa. An example of this is in 5 shown. The photovoltaic module 10 here has a circuit layout S whose visual appearance matches that of the outer layer 4 .

A generally rectangular photovoltaic element 10 is also shown in the figures, but other shapes are used in variants, for example to match a pattern of the outer layer 4 or to fill a corresponding non-rectangular shaped area of a product 12 in a visually appealing manner.

For a product 12 such as in 3 , which is made of the sheet material 2, the inner layer 8 faces inwards and is thus arranged on an inner side of the product 12. First of all, no particular requirements are made of the inner layer 8 with regard to the permeability of light L, in particular. In the present case, however, the inner layer 8 is designed to be opaque, so that the photovoltaic module 10 is not visible through the inner layer 8 and so that the interior of the product 12 is also not visible from the outside.

In the present case, the outer layer 4 consists of a TPU. In a variant that is not shown, the outer layer 4 consists of a silicone. The inner layer 8, on the other hand, consists of a textile, especially in particular a fabric, or leather, in order to be visually and haptically appealing. In a variant that is not shown, the inner layer 8 is also made of a TPU or a silicone.

In the exemplary embodiment shown, a first intermediate layer 18 is arranged between the photovoltaic module 10 and the outer layer 4 and a second intermediate layer 20 is arranged between the photovoltaic module 10 and the inner layer 8 . The intermediate layers 18, 20 are each formed as an adhesive layer and thereby connect the photovoltaic module 10 to the surrounding layers 4, 8 in a cohesive manner. In the present case, the intermediate layers 18, 20 each consist of a TPU or a silicone.

In the present case, the total layer thickness D1 is between 1 mm and 5 mm. The outer layer 4 has a layer thickness D2 in the range from 0.2 mm to 3.0 mm. The inner layer 8 has a layer thickness D3 in the range from 0.2 mm to 3.0 mm. The first intermediate layer 18 has a layer thickness D4 in the range from 0.2 mm to 3.0 mm. The second intermediate layer 20 has a layer thickness D5 in the range from 0.2 mm to 3.0 mm.

How out 2 As can be seen, the photovoltaic module 10 in the present case has two barrier layers 22, 24 on the outer circumference and is encapsulated by them. The barrier layers 22, 24 accordingly form two outermost layers of the photovoltaic module 10 and protect the inner layers that are not shown in detail, in particular an active layer and electrodes, from environmental influences. In addition, the photovoltaic module 10 can be integrated into the planar material 2 in a non-destructive manner and connected to the other layers 4, 8. In addition, the barrier layers 22, 24 also have a mechanically stabilizing and protective effect. The barrier layers 22, 24 are made from PET here.

As is clear from the figures, the core layer 6 in the present case only extends over a partial area of the planar material 2 so that the outer layer 4 is connected directly to the inner layer 8 outside of this partial area. The partial area is generally identical to the overlapping area 14. As a result, an edge area 26 is formed, which completely and without interruption surrounds the core layer 6 and specifically the photovoltaic module 10 and in which the inner layer 8 and the outer layer 4 are connected directly to one another. The edge area 26 here has an edge width B in the range from 0.5 mm to 10 mm.

The product 12 has as in 4 shown a charging port 28, which is connected to the photovoltaic module 10, for charging a mobile device 30. The charging port 28 is, for example, a USB port.

In one variant, instead of the mobile terminal device 30, an energy store is connected to the charging connection 28, which is then charged when light L is irradiated. This variant is not shown per se, but results from 4 by replacing the mobile terminal device 30 with an energy store. The mobile terminal device 30 is then connected indirectly to the charging connection 28 via the energy store and charged accordingly via the interposed energy store. Irrespective of the state of charge of the mobile terminal device 30, the local energy store is then charged when light L is present, by means of which the mobile terminal device 30 can then be charged when there is an acute need, regardless of whether there is light at that time or not.

The product 12 has an inner pocket 32 that is independent of the rest of the product and can be removed, in which the mobile terminal device 30 or the energy store is accommodated. This inner pocket 32 is fastened in the product 12 via a detachable connection (not shown).

Furthermore, the mobile product 12 shown here has a control unit 34, which is designed to disconnect the photovoltaic module 10 or parts thereof from the circuit in the event of shadowing. This counteracts the problem of possible shading, specifically partial shading, of the photovoltaic module 10 . In the case of complex-shaped and three-dimensional objects such as the product 12 described here, there is a risk that one or more parts thereof and thus also parts of the photovoltaic module 10 will be shaded simply because of the shape of the product 12 . The control unit 34 now disconnects the shaded parts of the photovoltaic module 10 from the circuit either automatically or manually. In 3 sensors 36 are shown, which measure the intensity of the incident light L and pass it on to the control unit 34, which then automatically switches off the shaded parts of the photovoltaic module 10 in the event of shading. In an alternative or in addition that is not shown, manual control takes place using a corresponding switch or, for example, software-controlled and carried out by the user, for example using a smartphone app.

Reference List

2

surface material

4

outer layer

6

core layer

8th

inner layer

10

photovoltaic module

12

product

14

overlap area

16

surface texturing

18

first intermediate layer

20

second intermediate layer

22, 24

barrier layer

26

edge area

28

charging port

30

mobile device

32

inside pocket

34

control unit

36

sensor

B

margin width

D1

total layer thickness

D2, D3, D4, D5

layer thickness

L

light

M

template

S

circuit layout

Claims (15)

Flat material (2), which has three layers (4, 6, 8), namely an outer layer (4), an inner layer (8) and a core layer (6), - the core layer (6) between the outer layer (4) and the inner layer (8) is arranged, - wherein the core layer (6) has an organic photovoltaic module (10), which is connected to the outer layer (4) and the inner layer (8), - wherein the inner layer (8) and the outer layer (4) together form the photovoltaic module (10 ) completely and overlap with it in an overlapping area (14) so that the photovoltaic module (10) is covered, - the outer layer (4) being transparent at least in the overlapping area (10) in such a way that this light (L) can reach the photovoltaic module (10) lets through, for generating energy, - the outer layer (4) being formed at least in the overlapping area (14) in such a way that it has a textile or leather-like feel, - the outer layer (4) having a surface structure (16), to form the textile or leather-like feel. Surface material (2) according to claim 1 , wherein the surface structure (16) is an embossing. Surface material (2) according to one of Claims 1 or 2 , wherein the outer layer (4) consists of a TPU or a silicone. Surface material (2) according to one of Claims 1 until 3 , wherein the inner layer (8) is designed to be opaque, so that the photovoltaic module (10) is not visible through the inner layer (8). Surface material (2) according to one of Claims 1 until 4 , wherein the inner layer (8) consists of a textile or leather. Flat material (2) according to one of Claims 1 until 5 , wherein the outer layer (4) has a pattern (M) which is visible from the outside, and wherein the photovoltaic module (10) has a circuit layout (S) which is designed in such a way that it visually corresponds to the pattern of the outer layer (4). . Surface material (2) according to one of Claims 1 until 6 , wherein a first intermediate layer (18) is arranged between the photovoltaic module (10) and the outer layer (4), wherein a second intermediate layer (20) is arranged between the photovoltaic module (10) and the inner layer (8), the first intermediate layer ( 18) and the second intermediate layer (20) are each formed as an adhesive layer and thereby connect the photovoltaic module (10) to the inner layer (8) and the outer layer (4) in a materially bonded manner. Surface material (2) according to claim 7 , wherein the intermediate layers (18, 20) each consist of a TPU or a silicone. Surface material (2) according to one of Claims 1 until 8th , The photovoltaic module (10) having two barrier layers (22, 24) on the outer circumference and being encapsulated by them. Surface material (2) according to claim 9 , wherein the two barrier layers (22, 24) are each formed as a PET film. Surface material (2) according to one of Claims 1 until 10 , wherein in this case the core layer (6) only extends over a partial area, so that the outer layer (4) is connected directly to the inner layer (8) outside of this partial area. Product (12) which is at least partially made of a sheet material (2) according to one of Claims 1 until 11 is manufactured and which has a charging connection (28) which is connected to the photovoltaic module (10) for charging a mobile terminal device (30) by means of the photovoltaic module (10). Product (12) after claim 12 , which is selected from a group of products (12), comprising: transport and storage containers, bags, suitcases, means of transport, outdoor and camping products, inflatable boats, boat accessories, clothing, caps, hats, caps. Product (12) according to any one of Claims 12 or 13 , wherein this has a control unit (34) which is designed to separate the photovoltaic module or parts thereof in the event of shading from the circuit. Method for producing a sheet material (2) which has three layers (4, 6, 8), namely an outer layer (4), an inner layer (8) and a core layer (6), - the core layer (6) between the outer layer (4) and the inner layer (8) is laminated in, - the core layer (6) having a photovoltaic module (10) which is connected to the outer layer (4) and the inner layer (8), - the photovoltaic module (10) is covered in that it is arranged so that it overlaps the inner layer (8) and the outer layer (4) in an overlapping area (14) and is completely enclosed together by the inner layer (8) and the outer layer (4), - at least in the overlapping area ( 14) the outer layer (4) is made transparent in such a way that this light (L) reaches the photovoltaic module (10) lets through, for generating energy, - the outer layer (4) being designed at least in the overlapping area (14) in such a way that it has a textile or leather-like feel, - the outer layer (4) having a surface structure (16) for forming the textile or leather-like feel.

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