Development and Testing of Lightweight Photovoltaic Modules for Vehicle-Integrated Applications Using Epoxy Resins and Fiberglass

The integration of photovoltaic (PV) technologies in electric vehicles (Vehicle-Integrated Photovoltaics, VIPV) addresses key challenges such as limited range and dependence on grid-based recharging. This study focuses on the development of lightweight photovoltaic modules for vehicular applications, using epoxy resins and fiberglass as encapsulation materials. The research follows a five-step methodology: initially, the thermal and mechanical properties of the materials, including thermal expansion (CTE), water vapor transmission rate (WVTR), and Young’s modulus are characterized to evaluate the material suitability for VIPV. Subsequently, six-cell mini-modules (MIMO) are fabricated using the characterized materials into a functional prototype. The encapsulation process is expected to introduce a cell-to-module loss of a maximum 3% efficiency loss. The MIMOs are subjected to a structural integrity test emulating vehicular vibrations and are electrically and structurally characterized by means of I-V curves and electroluminescence (EL) imaging respectively, before and after being subjected to the vibration test. The structural integrity tests, performed with a Brüel & Kjær shaking table, reproduce the dynamic stresses experienced in real vehicle driving conditions. Post-vibration tests re-evaluate the electrical and mechanical properties of the MIMOs, expecting retention of at least 90% of initial electrical performance after testing. These findings are expected to validate the suitability of the selected materials and design framework for vehicular integration. This research aims to advance VIPV technologies, supporting the development of lightweight photovoltaic modules that enhance electric vehicle performance and promote sustainable mobility solutions.