NL2036785B1

NL2036785B1 - Assembly, method and vehicle

Info

Publication number: NL2036785B1
Application number: NL2036785A
Authority: NL
Inventors: Ferdinand Maria Janssen Laurens; Scheirlinck Erik; Jalke Hoex Thomas
Original assignee: Tux Mobility B V
Priority date: 2024-01-11
Filing date: 2024-01-11
Publication date: 2025-07-22
Also published as: WO2025151028A1; WO2025151028A8

Abstract

The invention relates to a method for forming an assembly including a panel and a photovoltaic module. The method comprises a step of providing a first semi-finished product which forms the panel. Said panel may for instance be a roof panel or a body panel of a vehicle. The method also comprises a step of providing a second semi-finished product which forms the photovoltaic module, Le. a preformed photovoltaic module. Said photovoltaic module comprises a front sheet; a back sheet; and solar cells encapsulated between the front sheet and the back sheet by means of at least a first encapsulant. Preferably, a first encapsulant is provided between the front sheet and the solar cells and a second encapsulant provided between the solar cells and the back sheet. It is noted that said photovoltaic module is relatively flexible in comparison to the panel to which it is to be adhered. The method further comprises a step adhering the photovoltaic module, substantially over its entire back surface, to the panel. [Fig. 3]

Description

Title: Assembly, method and vehicle

The invention relates to an assembly comprising a panel, such as for instance a roof panel of a vehicle, and a photovoltaic module, or so-called solar panel, attached to said panel.

It is known in the art to provide roof panels of vehicles, or other panels, with photovoltaic modules.

For example, it is known to retrofit vehicles, such as for example campervans or motorhomes, with rigid solar panels which for instance are simply screwed onto vehicle, for instance above the roof of the vehicle. Disadvantages thereof may for instance lie in that the solar panels can be stolen relatively easily, as they for instance may be simply unscrewed. Furthermore, the solar panels may, for instance due to that they can heavily increase drag, have a negative impact on the performance of the vehicles, for instance in view of driving noises and energy consumption while driving.

Besides, perhaps even more important, such rigid solar panels may be relatively heavy, in particular due to having a glass front sheet and/or glass back sheet. Such relatively heavy solar panels may be very disadvantageous, in particular in case they are used with a relatively light electric vehicle (EV), such as for instance an electric three wheeler, such as an electric rickshaw or a three wheel electric moped, of which the weight may be relatively heavily increased by such solar panel.

Further, it is known to retrofit vehicles with flexible solar panels, or so-called flexible photovoltaic modules, which, usually in contrast to rigid solar panels, may be free of any glass layer as front sheet or back sheet, but which can have a plastic top sheet as well as a plastic back sheet. In these known assemblies, such flexible solar panels are simply adhered to a body part of the car, such as a roof, trunk lid or bonnet, for instance by means of double-sided tape or the like. This may allow for a relatively simple installation. Although such flexible solar panels, which may also be relatively thin in comparison to rigid solar panels having a glass top layer, may relatively neatly connect to the surface of the respective body part to which it is adhered, as the flexible solar panels may be pliable to at least some extent and may therefore substantially neatly follow curvatures of said body part, the lifespan of the flexible solar panels may usually be relatively short, for instance as they may tend to damage relatively fast in comparison to relatively rigid photovoltaic modules.

Furthermore, it is known to provide vehicles with more integrally formed photovoltaic modules, which may be more integrated with the vehicle then some of the above mentioned prior art photovoltaic modules or so-called solar panels. For example, there are known vehicles with assemblies in which solar modules are encapsulated under safety glass top layer in order to enable a relatively long life for their solar modules, wherein these assemblies are an integral part of either the roof or the bonnet of the vehicle. Although theft of such more integrally formed photovoltaic modules may be counteracted as they cannot be simply taken off from the vehicle, and although the glass may form a relatively rigid and structural layer of the photovoltaic module which may counteract damage relatively well as the rigidity of the photovoltaic module may counteract relatively well that its solar cells could be unintentionally bend, it can be considered as a substantial disadvantage of these assemblies that the glass is relatively heavy, which in particular may be a relatively large disadvantage in case the vehicle is a relatively light electric vehicle (EV), such as for instance an electric three wheeler, such as an electric rickshaw or a three wheel electric moped.

It is an object of the present invention to provide an alternative assembly comprising a panel, such as for instance a roof panel of a vehicle, and a photovoltaic module attached to said panel. In particular, it can be an object of the invention to provide an assembly having a panel, such as for instance a roof panel of a vehicle, and a photovoltaic module attached to said panel, wherein at least one of the disadvantages of prior art assemblies is counteracted. More in particular, the invention may aim to provide an assembly comprising a panel, such as for instance a roof panel of a vehicle, and a photovoltaic module attached to said panel, wherein at least one of the disadvantages mentioned above is counteracted. In embodiments, the invention may aim at providing an assembly including a panel, in particular a body part panel of a vehicle, and a photovoltaic module attached to said panel, which assembly on the one hand may be relatively lightweight, and which on the other hand may facilitate that it can have a relatively long life.

Thereto, the present disclosure provides for an assembly comprising a panel, such as for instance a roof panel or a body panel of a vehicle, and a photovoltaic module attached to said panel, wherein the photovoltaic module is relatively flexible in comparison to the panel to which it is being attached, and wherein the photovoltaic module is adhered to the panel substantially over the entire back surface of the photovoltaic module.

It is noted that the photovoltaic module is thus relatively flexible in comparison to the panel. It will be appreciated that the panel, or at least one or more portions thereof onto which the photovoltaic module is to be adhered, may be relatively rigid with respect to said photovoltaic module. In the finally formed assembly, by far the majority of the stiffness of said assembly may be provided not by the relatively flexible photovoltaic module or so-called solar panel, but by the panel. At least in embodiments, the structural capacity and/or the rigidity of the assembly may thus be provided substantially by the panel onto which the relatively flexible photovoltaic module has been adhered. Further, it is noted that the panel may be considered to be a structural panel or a supporting panel.

Besides, it will be appreciated that, at least in the context of the assembly, the feature that the photovoltaic module is relatively flexible in comparison to the panel to which it is being attached, can be interpreted as that prior to adhering said photovoltaic module to said panel, said photovoltaic module was relatively flexible in comparison to the panel to which it was not yet attached, in particular when measured at room temperature, such as for instance a temperature of about 20 °C.

By providing a relatively flexible photovoltaic module, in particular one having aplastic front sheet and a plastic back sheet, the photovoltaic module can for instance be relatively lightweight, which may result in a relatively lightweight assembly. By adhering said relatively flexible photovoltaic module not only at certain areas of its back surface or so-called rear surface, such as for example only at the peripheral edges of its back surface or only at the peripheral edges and additionally also at one or multiple relatively centrally located surface area parts of its back surface, but by instead adhering said relatively flexible photovoltaic module over substantially its entire back surface to the panel, it can be enabled that substantially any part of the back surface is itself directly attached to the panel. As such, the present assembly can thus form a relatively rigid unity, in particular when compared to prior art assemblies in which a relatively flexible photovoltaic module is adhered to a vehicle panel by means of double-sided tape not applied to each and every part of the back surface of said flexible photovoltaic module. The relatively rigid unity of the present assembly can counteract relatively well that the flexible photovoltaic module may deform independently of the panel to which it is adhered. Surprisingly, this can counteract relatively well that the photovoltaic module might get damaged. In particular, due to that the initially flexible photovoltaic module forms a rigid unity with the panel to which is adhered, it can be counteracted relatively well that the photovoltaic module can locally deform independently of said panel, which is relatively rigid. Hence, contrary to a known flexible photovoltaic module only locally adhered to a vehicle panel, which may locally, i.e. at a spot where it is not adhered to the vehicle panel, temporarily bend relatively much independently of said vehicle panel, it may be counteracted that the present photovoltaic module could locally bend, in particular independently from the panel. As such, it can thus be counteracted relatively well that, for instance due to a local impact, such as for example due to incoming hail stones, the photovoltaic module of the present assembly can locally bend beyond a local bending radius threshold, as the relatively rigid panel to which it is adhered, also at that specific location, can counteract bending of the photovoltaic module at said specific location.

In other words, by adhering a relatively flexible photovoltaic module substantially over its entire rear surface or so-called back surface to the panel, the present assembly on the one hand may be relatively lightweight, and on the other hand may counteract relatively well that it gets damaged and may therefore thus facilitate that it may have a relatively long life.

In addition, the present assembly may not only be relatively lightweight, but it may also be relatively cost efficient and/or inexpensive to produce the assembly.

It is noted that the photovoltaic module or so-called solar panel may include a front sheet and a back sheet, for instance each made of a foil material, and that said photovoltaic module may further include solar cells which have been encapsulated between said front sheet and said back sheet using at least a first encapsulant. This may preferably be done using a first encapsulant provided between the front sheet and the solar cells and using a second encapsulant provided between the solar cells and the back sheet. Although not necessarily, said first encapsulant and/or said second encapsulant may for example be a polyolefin elastomer (POE) encapsulant.

However, other encapsulants may be possible in alternative embodiments, such as for instance an ethyl vinyl acetate (EVA) encapsulant. Additionally or alternatively, the first encapsulant and the second encapsulant may be formed by the same or a similar encapsulant material or composition, and may for example both be a polyolefin elastomer (POE) encapsulant.

By adhering the photovoltaic module to the panel by means of a further encapsulant, preferably wherein said further encapsulant is substantially the same as 5 or similar to the first encapsulant and/or the second encapsulant, if any, the production of the assembly may for instance be relatively simple and/or relatively cost efficient, for example due to that only relatively few different materials and/or relatively few different productions means may be needed. Additionally or alternatively, it may provide advantages at the end of the economic life of the of the assembly, for instance as it may facilitate for relatively simple and/or relatively efficient and/or relatively environmental friendly disposal or reuse or recycling or the like.

Advantageously, both the back sheet of the photovoltaic module and the further encapsulant may comprise polymer material, and said polymer material of the further encapsulant may then be cross-linked with the polymer material of the back sheet.

Additionally or alternatively, both the panel and the further encapsulant may comprise polymer material, and said polymer material of the further encapsulant may then be cross-linked with the polymer material of the panel. By providing such cross-linking between the further encapsulant and, at least one of and preferably both, the back sheet and the panel, a relatively strong and/or relatively durable adhesion or so-called bonding between the panel and the photovoltaic module may be facilitated. This may further facilitate that said photovoltaic module and said panel may form a relatively rigid unity which may counteract relatively well and/or which may counteract for a relatively long period of time that the photovoltaic module could unintentionally bend irrespective of the panel and may thereby thus counteract damage to the photovoltaic module relatively well and/or for a relatively long period of time.

For instance for facilitating such cross-linking, the panel, in particular at least at its surface facing the photovoltaic module, may preferably comprise or be made of a thermoplastic polymer, such as for instance polypropylene (PP) or such as for instance polyethylene (PE). In embodiments, a panel comprising polypropylene may comprise a composite material including a polymer which then may be reinforced, for example with glass fiber. An advantage of using a panel of which at least the surface facing the photovoltaic module comprises, and preferably substantially the entire panel is made of, a reinforced composite plastic material such as for example glass fiber reinforced polypropylene (PP GF), may be that the panel is relatively stiff, which may counteract to a relatively large extent that the panel would unintentionally deform when the photovoltaic module is adhered thereon, in particular when such adhering is done while the panel is heated, for example in order to allow cross-linking.

Additionally or alternatively, the back sheet of the photovoltaic module may preferably comprise or be made of a thermoplastic polymer, such as for instance polypropylene (PP).

It is noted that although material of the back sheet may preferably be cross-linked with material of an encapsulant in order to adhere the photovoltaic module to the panel, this is not necessary. It is noted that the back sheet may adhered by other means. Besides, it is noted that, additionally or alternatively, the back layer of the photovoltaic module does not need to comprise polymer material, and if it nevertheless does, the polymer material does not need to be present at the outer or rear surface of the back sheet. For example, the outer or rear surface of the back sheet, which may be in the form of an flexible integrated conductive back sheet, may comprise and/or may be made of another material, for instance a metal or metal alloy, such as for example copper.

Although the panel, in particular at least at its surface facing the photovoltaic module, may in embodiments comprise or be made of a thermoplastic polymer, said panel, in particular at least at its surface facing the photovoltaic module, may in alternative embodiments comprise or be made of a thermosetting polymer or so-called thermoset. For example, the panel may comprise or be made of a thermoset or a compound based on a thermoset, such as for instance a glass fiber reinforced thermoset. For example, the panel may be made of, or at least comprises, a polyester resin, in particular a glass fiber reinforced polyester resin.

For instance in such embodiment, the panel may for example be formed by means of injection moulding.

The present disclosure also relates to a method for forming an assembly including a panel and a photovoltaic module.

In embodiments, the method comprises the steps of providing a first semi-finished product which forms the panel and providing a second semi-finished product which forms the photovoltaic module comprising a front sheet, a back sheet, and solar cells encapsulated between the front sheet and the back sheet by means of at least a first encapsulant, preferably by means of a first encapsulant provided between the front sheet and the solar cells and a second encapsulant provided between the solar cells and the back sheet. Said photovoltaic module is relatively flexible in comparison to the panel to which it is to be adhered. Said method further comprises a step of adhering the photovoltaic module, substantially over its entire back surface, to the panel.

By adhering the relatively flexible photovoltaic module substantially over its entire back surface or so-called rear surface to the panel, the present method may facilitate producing an assembly which on the one hand may be relatively lightweight, and on the other hand may be relatively sturdy and/or relatively durable and/or relatively damage resistant.

Furthermore, the present disclosure relates to a vehicle.

Advantageous embodiment according to the invention are described in the appended claims.

By way of non-limiting examples only, embodiments of the present invention will now be described with reference to the accompanying figures in which:

Fig. 1 shows a schematic perspective view of two vehicles each including a respective embodiment of an assembly according to an aspect of the present disclosure;

Fig. 2 shows a schematic perspective exploded view of an embodiment of a photovoltaic module forming a semi-finished product to be used in an embodiment of an assembly according to an aspect of the present disclosure; and

Fig. 3 shows a schematic exploded cross-sectional view of a laminator machine provided with a preformed panel and a preformed photovoltaic module to form an assembly according to an aspect of the present disclosure.

It is noted that the figures show merely preferred embodiments according to the present disclosure. In the figures, the same or similar reference signs or numbers refer to equal or corresponding parts.

Figure 1 shows two vehicles 1 each including an assembly 2 comprising a panel 4 and a photovoltaic module 3 adhered to said panel 4 substantially over the entire back surface or so-called rear surface 3’ of the photovoltaic module 3. Although here both of the two exemplary embodiments of the vehicle 1 are in the form of a three wheeler or so-called tricycle, in particular a rickshaw, the vehicle may be another vehicle, such as for instance another land vehicle, for example a coach (bus) or a truck, but it could for instance also be a vessel or a boat or yet another vehicle. It is noted that the vehicle 1 may preferably be a motor vehicle, more preferably an electric vehicle (EV), for instance such that at least a part of the power for powering the vehicle itself and/or for powering devices installed aboard the vehicle, such as for instance a cooling device or the like, may be provided by the photovoltaic module 3. In embodiments, the vehicle 1, 1a may be arranged for passenger transport.

Alternatively, or additionally, the vehicle 1, 1b may be arranged for freight transport.

In particular, the assembly 2 may for instance form a roof panel or a body panel of a vehicle 1. The assembly 2 may thus for instance form at least part of the bodywork of a vehicle 1. In embodiments, the assembly 2 can be a body part of the vehicle 1, such as for instance a bonnet part, a fender part or a trunk lid part. Further, it is possible that the assembly 2 can form a part of a cargo box, in particular part of a cargo box 10 or storage compartment 10 of the vehicle 1, as can be seen in the exemplary embodiment shown at the righthand side of figure 1.

As is the case in the here shown embodiments, the panel 4 forming part of said assembly 2 can in embodiments have a substantially curved outer surface onto which the photovoltaic module 3 is adhered. In particular, the curved outer surface may be formed by the panel's upper or front surface 4’ facing the photovoltaic module 3. Said outer surface 4° may in particular embodiments be formed as a double curved surface 4', as for instance can be seen relatively well in Figure 1.

The method for forming the assembly 2 also comprises a step of providing the panel 4 onto which the photovoltaic module 3 or so-called solar panel 3 is to be adhered. In embodiments, the provided preformed panel 4 may be a moulded part, such as for instance an injection moulded part or a thermoformed part. However, the panel may 4 be formed alternatively. For example, the panel may be formed by compression moulding, and may for instance be made of glass fiber reinforced polypropylene (PP GF). As another example, the panel may for instance be formed as a sandwich panel, which then may have a lightweight core, for example a core made at least partly in the form of a honeycomb structure and/or for example a core formed at least partly of a foam material.

It will be appreciated that although the panel 4 may thus have a substantially curved outer surface onto which the photovoltaic module 3 is adhered, at least the outer surface onto which the photovoltaic module 3 is adhered, and preferably even substantially the entire panel, may be substantially flat in alternative embodiments.

Although the assembly 2 may in advantageous embodiments thus form part of the vehicle 1 itself, the assembly 2 may in alternative embodiments be separately mounted to the vehicle 1, which for instance may be advantageous in case a respective part 11 of the vehicle 1, such as for example an integrally formed cargo box 10’, such as for example a cargo box made by rotational moulding or for example an integrally blow moulded cargo box, may be relatively difficult and/or relatively expensive to form, and/or for instance when such respective part 11 of the vehicle may be relatively large which could for instance make it relatively difficult to fit it inside a laminator machine.

With respect to the photovoltaic module 3, it is noted that it is relatively flexible in comparison to the panel 4 to which it is being adhered. In the finished assembly 4, the panel 4 can thus provide for a larger portion of the stiffness of said assembly 4 than the photovoltaic module 3. In particular, the photovoltaic module 3, which initially, thus before it is adhered substantially over its entire surface to the panel, is relatively flexible, may in embodiments contribute little to no part of the stiffness of the final assembly.

As can be seen relatively well in figure 2, which shows a schematic perspective exploded view of an embodiment of the photovoltaic module 3 forming a semi-finished product 3a to be used in an embodiment of an assembly 4 according to an aspect of the present disclosure. In particular, the photovoltaic module 3 can include solar cells 33 encapsulated between a front sheet 34 and a back sheet 35 by means of a first encapsulant 31 provided between the front sheet 34 and the solar cells 33 and a second encapsulant 32 provided between the solar cells 33 and the back sheet 35.

Regarding the front sheet 34 of the photovoltaic module 3, it is noted that said front sheet 34 may be made of a thermoplastic, in particular an optically transparent thermoplastic such as for example polyethylene terephthalate (PET), ethylene tetrafluoroethylene (ETFE), or polymethyl methacrylate (PMMA).

As mentioned, the assembly 4 is formed by adhering the photovoltaic module 3 substantially over its entire back surface 3’ to the panel 4. Figure 3 shows a schematic cross-sectional view of an exemplary embodiment of an apparatus 6 in which the assembly 4 can be manufactured. Here, the apparatus 6 is for instance formed as a laminator machine 8, but it will be appreciated by the skilled person that another apparatus and/or other manufacturing equipment may be used alternatively, or additionally. The apparatus 6 may be used for forming the assembly 2 including the panel 4 and the photovoltaic module 3.

For clarity reasons, in the here shown exploded view the top part 6a of the apparatus 6 is here lifted with respect to the lower part 6b. However, this does not necessarily mean that the top part 6a of the laminator machine 6 or other apparatus 6 needs to be movable with respect to its lower part 6b, for example as portions of the assembly 2 to be formed, in particular its panel 4, its photovoltaic module 3 and its further encapsulant 5, if any, may, for instance sideways, be conveyed into the laminator machine 6 or other apparatus 6.

The panel 4, which for instance may be a moulded part of a plastic material or composite, for instance injection moulded or thermoformed, forms a first semi-finished product 4. The panel 4 may for instance also be formed differently, for instance as a sandwich panel.

The method also includes a step of providing a second semi-finished product 3.

Said second semi-finished product 3 is formed by the photovoltaic module. In other words, the photovoltaic module 3 is thus a preformed part, in particular produced separately from the panel 4. Said photovoltaic module 3 comprises a front sheet 34, a back sheet 35, and solar cells 33 encapsulated between the front sheet 34 and the back sheet 35 by means of at least a first encapsulant 31, preferably by means of a first encapsulant 31 provided between the front sheet 34 and the solar cells 33 and a second encapsulant 32 provided between the solar cells 33 and the back sheet 35.

It is noted that said photovoltaic module 3 is relatively flexible in comparison to the panel 4 to which it is to be adhered.

The method further comprises a step of adhering the relatively flexible preformed photovoltaic module 3 onto the panel 4 over substantially the entire back surface or so-called rear surface 3’ of the photovoltaic module 3. As such a relatively rigid unity can be formed in which substantially no portion of the photovoltaic module 3 can substantially bend irrespective of the panel 4 to which it is adhered.

Preferably, the adhering may be done by means of a further encapsulant 5.

Advantageously, the further encapsulant 5 may be made of a plastic material, preferably a polymer, more preferably an elastomer, such as for example a polyolefin elastomer (POE) encapsulant or an ethyl vinyl acetate (EVA) encapsulant. However,

other encapsulants are possible as well, such as for instance a thermoplastic polyolefin (TPO) encapsulant.

In embodiments, the panel 4, in particular at its upper or front surface 4’ facing the photovoltaic module 3, may comprise polymer material. The further encapsulant 5 may then also comprises a polymer material. During the manufacturing of the assembly 2, the polymer material of the further encapsulant 5 can then become cross-linked with the polymer material of the panel 4, which panel, in particular at least at its surface 4’ facing the photovoltaic module 3, may preferably comprise or be made of a thermoplastic polymer, such as for instance polypropylene (PP). However, other encapsulants are possible as well, such as for instance a thermoplastic polyolefin (TPO) encapsulant.

It is noted that the further encapsulant 5 may preferably be the same as or similar to the first encapsulant 31 and/or the second encapsulant 32, if any.

Advantageously, the step of adhering the photovoltaic module 3, substantially over its entire back surface 3’, to the panel 4 includes a sub-step of pressing the panel 4 and the preformed photovoltaic module 3 together with the further encapsulant 5 sandwiched therebetween, This may for instance be done using a laminator machine 6.

In order to press the photovoltaic module 3 and the panel 4 together, the panel 3 may be supported by means of a support structure 7. The support structure 7 then thus presses against the panel 4, in particular against a surface 4” of said panel 4 which faces away from the photovoltaic module 3. For example, said support structure 7 may be in the form of a mould 8, which may have a support surface shaped as a counterpart of the preformed panel 4. Although in the exemplary embodiment shown in Figure 3 the support structure 7 may form a substantially separate part 8 placed within the laminator machine 6, support structure 7 can be formed differently.

For example, when the preformed panel 4, or at least its back or rear or bottom surface 4’ facing away from the photovoltaic module 3 is a substantially flat surface, i.e. a non-curved surface, the support structure 7 can be formed by part of the laminator machine 6 itself, for instance by a plate 60, in particular a heating plate 60’, thereof.

It will be appreciated that the support structure 7 may form a first pressing element 9a.

Further, a second pressing element 9b may be used to press the photovoltaic module 3 and the panel 4 together, in particular by pressing against a surface 3” of said preformed photovoltaic module 3 which faces away from the panel 4. In embodiments, said second pressing element 9b can be formed by a flexible sheet 61, for instance a silicone membrane sheet of the laminator machine 6, as can be seen in

Figure 3. In the here shown exemplary embodiment of the laminator machine 6, said machine 6 is very schematically shown and is shown in an exploded view. It will be appreciated that during a step in which the flexible sheet 61 presses against the photovoltaic module 3, a first room 62, in particular a bottom room, in which the photovoltaic module 3 and the panel 4 onto which it is being adhered are provided and which room 62 may preferably be at least partly defined by the flexible sheet 61, may be closed off. This may for instance facilitate to substantially create a vacuum or a partial vacuum in said first room 62. This may for example not only facilitate that the flexible sheet 61 can be pushed against the photovoltaic module 3 by a relatively high pressure present at the opposite side of the flexible sheet 61, but additionally, or alternatively, the vacuum may remove gas, in particular air, from between different layers 3, 5, 4 that will be combined into the assembly 2, thereby for instance counteracting that air could be trapped which could otherwise prevent that he photovoltaic module 3 is adhered over its entire surface to the panel 4, which is highly undesirable.

Although the vacuum or partial vacuum may facilitate that the flexible sheet 61 can be pushed against the photovoltaic module 3, the pressure at the opposite side of said flexible sheet 61 may additionally, or alternatively, be increased, for instance by pumping a fluid, in particular a gas, for instance air, into a second room or chamber 63, in particular an upper room.

However, it is noted that the pressing may be done differently. For example, the second pressing element 9b may be formed differently. In embodiments, said second pressing element 9b may for example formed as a second mould part, which may preferably be still resilient to a certain extent, for example by forming it from a silicon or rubber like material or composite.

Preferably, the further encapsulant 5 can be heated before the panel 4 and the preformed photovoltaic module 3 are pressed together with the then thus heated further encapsulant 5 therebetween. For example, the heating may take place at least partly inside the laminator machine 6 or other apparatus. Advantageously, when the panel 4 and the preformed photovoltaic module 3 are pressed together with the heated further encapsulant 5 therebetween, said further encapsulant 5 and/or the photovoltaic module 3 as a temperature of at least 100 °C, preferably at least 120 °C, more preferably at least 125 °C, yet more preferably at least 130 °C, such as for example at least 135 °C. Such temperatures, such as for example one of at least 125 °C or at least 130 °C, may, at least in embodiments, for instance facilitate cross-linking.

It will be appreciated that the temperature should preferably also not be too high, and may for instance be lower than 200 °C, for instance no more than 180 °C, preferably no more than 165 °C.

It will be appreciated that not only the further encapsulant 5 may be heated in order to adhere the preformed photovoltaic module 3 onto the panel 4, but that also said preformed photovoltaic module 3 and/or the panel 4 may be heated before said panel 4 and said photovoltaic module 3 are pressed together with the heated further encapsulant 5 therebetween.

It is noted that, at least in some embodiments, the coefficient of thermal expansion of the first semi-finished product 4 forming the panel 4 and the coefficient of thermal expansion of the second semi-finished product 3 forming the photovoltaic module 3 may differ to a certain extent, as for instance the first and second encapsulant 31, 32 and the solar cells 33 may have a coefficient of thermal expansion which may substantially differ from a coefficient of thermal expansion of a polymer material of which the panel 4 and/or the front sheet 34 and/or the rear sheet 35 are made.

For instance in order to counteract stresses in the final assembly 2, the method for forming the assembly 2 may comprise one or multiple additional steps.

In advantageous embodiments, the assembly 2 that is being formed may be cooled down, at least to a certain extent, while the photovoltaic module 3 and the panel 4 are still kept pressed together. For example, the assembly 2 may be cooled down to below a certain threshold temperature, which for instance may be 120 °C, preferably 100 °C, more preferably 80 °C, yet more preferably 60 °C. Such cooling step may for instance counteract stresses in the final assembly 2 to at least a certain extent.

The cooling down may preferably be executed using active cooling, more preferably by means of a cooling agent, such as a coolant or water, which may flow through one or more cooling channels 81 located in the support structure 8, if any.

Cooling down the assembly while substantially keeping the photovoltaic module 3 and the panel 4 pressed together may facilitate a relatively strong and/or relatively durable bonding.

Alternatively, or additionally, the method for producing the assembly 2 may comprise a so-called annealing step. For example, the annealing step may comprise the following sub-steps.

In a first sub-step, the already formed assembly 2 can be heated, in particular reheated, preferably heated to at least a certain temperature. Said certain temperature may for example be a temperature of at least 70 °C, more preferably at least 75 °C, yet more preferably at least 80 °C, such for instance about 85 °C. It is noted that said certain temperature may alternatively or additionally be such that it substantially is above the recrystallization temperature of any used polymer material, in particular substantially above the recrystallization temperature of. any polymer material of the panel 4, especially at its upper or front surface 4’ facing the photovoltaic module 3; and/or any polymer material of the further encapsulant 5, if any; and/or any polymer material of the photovoltaic module 3, in particular at its rear surface 3’.

Subsequently, the heated assembly 2 may then subsequently be kept heated up for a certain period of time. Preferably, it can be kept substantially heated up at or above a certain threshold temperature, such as for instance a threshold temperature of at least 70 °C, more preferably at least 75 °C, yet more preferably at least 80 °C, such as for instance about 85 °C. Besides, the said certain period of time may for instance be at least half an hour, at least one hour, or at least one and half hours, such as for example about two hours.

In a further sub-step, the assembly which has been kept heated up for the certain period of time may then subsequently be allowed to cool down again.

Due to such annealing, polymers can be restructured to at least some extent, thereby for instance facilitating that stresses in the final assembly 2 can be counteracted to at least a certain extent, which may facilitate enabling in a relatively long lifespan for the photovoltaic module 3 and/or the assembly 2.

It is noted that for the purpose of clarity and a concise description features are described herein as part of the same or separate embodiments, however, it will be appreciated that the scope of the present disclosure may include embodiments having combinations of all or some of the features described.

Further, it is noted that the invention is not restricted to the exemplary embodiments described herein. |it will be understood that many variants are possible.

For example, the assembly may comprise multiple photovoltaic modules adhered to the panel, preferably wherein each of said multiple photovoltaic modules is adhered to the panel over its respective substantially entire rear surface.

Such and other variants will be apparent to the person skilled in the art and are considered to lie within the scope of the invention formulated in the following claims.

Claims

CONCLUSIONS

1. An assembly comprising: a panel, such as a roof panel or a vehicle body panel; and a photovoltaic module attached to said panel, the photovoltaic module being relatively flexible compared to the panel to which it is attached, and the photovoltaic module being attached to the panel by bonding said photovoltaic module to the panel substantially over the entire rear surface of said photovoltaic module.

An assembly according to claim 1, wherein the photovoltaic module comprises a front sheet and a back sheet, and wherein the photovoltaic module comprises solar cells encapsulated between the front sheet and the back sheet by means of at least a first encapsulant, preferably by means of a first encapsulant provided between the front sheet and the solar cells and a second encapsulant provided between the solar cells and the back sheet, and wherein the photovoltaic module is attached to the panel by means of a further encapsulant, preferably wherein said further encapsulant is substantially the same as or similar to the first encapsulant and/or the second encapsulant, if present.

Assembly according to claim 1 or 2, wherein the rear surface of the photovoltaic module comprises polymer material, the further encapsulant comprises polymer material, and said polymer material of the further encapsulant is cross-linked with the polymer material of the rear sheet, which rear sheet may preferably comprise or be made of a thermoplastic polymer, such as for example polypropylene (PP), and/or wherein the panel comprises polymer material, the further encapsulant comprises polymer material, and the polymer material of the further encapsulant is cross-linked with the polymer material of the panel, which panel, in particular at least on its surface facing the photovoltaic module, may preferably comprise or be made of a thermoplastic polymer, such as for example polypropylene (PP).

4. Assembly according to any of the preceding claims, wherein the assembly forms a body part of a vehicle, such as for example a roof part, a hood part, a mudguard part or a trunk lid part, or wherein the assembly forms part of a loading box, in particular a loading box of a vehicle, or wherein the assembly is mounted to a vehicle.

5. A method for forming an assembly comprising a panel and a photovoltaic module, the method comprising the steps of: providing a first semi-finished product forming the panel, which may be, for example, a roof panel or a vehicle body panel; and providing a second semi-finished product forming the photovoltaic module,

i.e. a preformed photovoltaic module, said photovoltaic module comprising a front sheet; a back sheet; and solar cells encapsulated between the front sheet and the back sheet by at least a first encapsulant, preferably by a first encapsulant provided between the front sheet and the solar cells and a second encapsulant provided between the solar cells and the back sheet, said photovoltaic module being relatively flexible compared to the panel to which it is to be attached, the method further comprising a step of: attaching the photovoltaic module over substantially its entire back surface to the panel.

A method according to claim 5, wherein the step of adhering the photovoltaic module to the panel over substantially its entire rear surface comprises a sub-step of pressing the panel and the pre-formed photovoltaic module together with a further encapsulant enclosed therebetween, for example by means of a laminating machine.

A method as claimed in claim 5 or 6, wherein the further encapsulant is heated before the panel and the preformed photovoltaic module are pressed together with the heated further encapsulant therebetween; and wherein the further encapsulant is subsequently allowed to cool.

A method according to claim 6 or 7, wherein the further encapsulant is made of a plastics material, preferably a polymer, more preferably an elastomer, such as, for example, a polyolefin elastomer (POE) encapsulant or an ethyl vinyl acetate (EVA) encapsulant.

A method according to any one of claims 6 to 8, wherein, when the panel and the preformed photovoltaic module are pressed together with the heated further encapsulant therebetween, the further encapsulant and/or the photovoltaic module has a temperature of at least 100°C, preferably at least 120°C, more preferably at least 125°C, even more preferably at least 130°C, such as for example at least 135°C.

10. A method according to any one of claims 6 to 9, wherein the preformed photovoltaic module is heated before the panel and the preformed photovoltaic module are pressed together with the heated further encapsulant therebetween;

wherein the panel and the preformed photovoltaic module are pressed together with the heated further encapsulant between them; and wherein the further encapsulant and the preformed photovoltaic module are then allowed to cool.

Method according to any of claims 5 to 10, wherein the front sheet of the preformed photovoltaic module is made of a thermoplastic, in particular an optically transparent thermoplastic such as, for example, polyethylene terephthalate (PET), ethylene tetrafluoroethylene (ETFE), or polymethyl methacrylate (PMMA).

Method according to any of claims 5 to 11, wherein the pre-formed photovoltaic module and the panel to which it is attached are pushed together while the panel is supported by means of a support structure, for example one in the form of a mould, which support structure then thus pushes against the panel, in particular against a surface of said panel facing away from the photovoltaic module.

Method according to any of claims 5-12, preferably according to claim 12, wherein, when said photovoltaic module and the panel are pushed together, a flexible sheet, for example a silicone membrane sheet from a laminating machine, presses against said preformed photovoltaic module, in particular against a surface of said preformed photovoltaic module that faces away from the panel.

Method according to any of claims 7 to 13, wherein the assembly being formed is cooled, for example cooled to below 100°C, preferably at least below 85°C, while the photovoltaic module and the panel remain pressed together, preferably wherein said assembly is cooled by means of active cooling, more preferably by means of a coolant, such as a coolant or water, flowing through for example one or more cooling channels located in the support structure, if present.

A method according to any one of claims 5 to 14, further comprising an annealing step, wherein: the already formed assembly is heated, in particular reheated, preferably to at least a certain temperature, such as for example a temperature of at least 70°C, more preferably at least 75°C, even more preferably at least 80°C, such as for example about 85°C; the heated assembly is then maintained heated for a certain period of time, preferably maintained substantially heated at or above a certain threshold temperature, for example a threshold temperature of at least 70°C, more preferably at least 75°C, even more preferably at least 80°C, such as for example about 85°C, said certain period of time being for example at least half an hour, at least one hour, or at least one and a half hours, such as for example about two hours; and the assembly having been heated for a certain period of time is then allowed to cool.

16. Assembly obtained at least partly by means of the method according to any of claims 5 to 15.

17. Vehicle, preferably a motor vehicle, more preferably an electric vehicle (EV), such as an electric three-wheeler, in particular a so-called electric rickshaw, comprising the assembly according to any of claims 1-4 and 16.