International audienceIn response to the marked increase in research activity and publications about Vehicle Integrated PhotoVoltaics (VIPV), this article is an attempt to identify the main constraints relative to the manufacturing of curved PV modules for automotive application and the interests of composite modules in this context. Two processes have been selected as better adapted to the automotive industrialization and in-mold integration of PV cells: Resin Transfer Molding (RTM) and thermocompression. A finite element analysis (FEA) to evaluate the mechanical strength of the resulting module is proposed. The aim of this numerical approach is to optimize the mechanical performance of the structure. First results were validated by a comparison of simulation outputs with 3-point bending test measurements

Boichon, Vincent

Brancaz, Xavier

Chabuel, Fabien

Duigou, Tatiana

Francescato, Pascal

Gaume, Julien

Habchi, Georges

Lagache, Manuel

Saffré, Philippe

Tenchine, Lionel

International audienceIn order to reduce the greenhouse gas emissions of vehicules, electric vehicles meet an increasing success. However, a key obstacle is the autonomy of their batteries. The integration of photovoltaic modules in car parts (VIPV: Vehicle Integrated PhotoVoltaics) is a relevant solution to minimize the battery size or provide power for the additional equipment. This solution is already being studied by car manufacturers like Toyota (Prius), Sono Motors (Sion), Lightyear (One) ... These manufacturers mostly use materials and processes traditionally used in the PV industry: glass and polymers for the materials and lamination for the process of integration of PV cells. However, this process is not well adapted for the automotive industry. Moreover, glass or polymer panels do not enable to minimize the weight of the vehicle and do not meet the mechanical constraints imposed by automotive standards for parts such as doors or bonnets.In 2019, the CEA revealed its first work on an electric vehicle assisted by solar energy, the CZen. This opened the way for an in-depth work on VIPV. Thus, the aim of this study lead together with the technical center IPC is to develop manufacturing processes for the integration of PV cells adapted to the automotive industry: Resin Transfer Molding and thermocompression. The materials used, glass fibre composites, are also yet not common in the PV industry. The index case is a 40 cm*40 cm panel with a double curvature. The main aspects of this study concern:- the choice of materials adapted for photovoltaic constraints, particularly with regard to transparency and ageing of the materials (norm IEC 61215);- the choice of materials and stacks adapted for the processes, especially in terms of permeability and impregnation of fibres;- the identification and selection of the parameters for the processes: temperature, pressure, dosing formulation ...;- the implementation and validation of a Finite Element Analysis model to predict the thermomechanical stresses resulting from the processes and optimize the mechanical properties of the module.Experimental tests validated the mechanical model and provided other properties like the photoelectric performance of these curved panels. Further research includes the optimization of the processes parameters for large structures and the optimization of the reliability and performance of the module

Boichon, V.

Brancaz, X.

Chabuel, F.

Francescato, P.

Gaume, J.

Lagache, M.

Saffré, P.

Tenchine, L.

HAL-CEA

VIPV: Process development of integrated photovoltaic cells in a double-curved composite structure for automotive application

HAL Descartes

HAL Université de Savoie

VIPV: Process development of integrated photovoltaic cells in a double-curved composite structure for automotive application

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HAL-CEA

HAL Descartes

HAL Université de Savoie

HAL Université de Savoie

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