abstract
Integration of photovoltaics (PV) into surfaces that are so far not used for electrical power generation often demands new designs of PV modules. Such new module shapes can include curvatures in three dimensions, which can in general not be handled in standard PV module production processes. In this work, an alternative lamination process using a flexible heat transfer mold (FlexHTM) is presented. The flexible heat transfer mold consists of deformable heat transfer cushions filled with a thermally conductive granulate. The mold supports the heat transfer from a flat heating element to a curved module stack and simultaneously prevents the module shape from deformation during vacuum lamination. The deformable properties enable the adaptation of the flexible heat transfer mold to differently shaped and structured PV modules, which is advantageous over the use of costly massive metallic molds. Several differently shaped PV modules for vehicle integration were manufactured from interdigitated back contact (IBC) solar cells on passenger car hoods with the FlexHTM method, showing its flexibility and ability to produce mechanically stable and aesthetically appealing curved VIPV modules.