Multifunctional composite panels and methods for the same

Patent metadata

Field	Value
Publication number	US-10923680-B2
Application number	US-201816157944-A
Country	US
Kind code	B2
Filing date	Oct 11, 2018
Priority date	Oct 11, 2018
Publication date	Feb 16, 2021
Grant date	Feb 16, 2021

Abstract

A method for fabricating a multifunctional composite panel is disclosed. The method can include forming a plurality of structural layers, and forming a plurality of photovoltaic layers adjacent the plurality of structural layers. Forming the plurality of structural layers can include forming alternating layers of a conductive organic material and an inorganic material. Forming the alternating layers can include forming a first layer from the conductive organic material, and forming a second layer adjacent the first layer from the inorganic material. The multifunctional composite panel can have a thickness of from about 1 mm to about 30 mm.

First claim

What is claimed is:

1. A method for fabricating a multifunctional composite panel, the method comprising:
forming a plurality of structural layers directly on a mandrel, wherein forming the plurality of structural layers on the mandrel comprises forming a plurality of alternating layers on the mandrel, wherein each of the plurality of alternating layers comprises a first layer and a second layer, and wherein forming the plurality of alternating layers comprises:
forming a first layer of each of the plurality of alternating layers from one or more polymers; and
forming a second layer of each of the plurality of alternating layers directly adjacent the first layer of each of the plurality of alternating layers, wherein the second layer of each of the plurality of alternating layers is formed from one or more of aluminum oxide (Al 2 O 3 ), graphene, silicon oxide, or combinations thereof;

forming a plurality of photovoltaic layers adjacent the plurality of structural layers, wherein the multifunctional composite panel has a thickness of from about 1 mm to about 30 mm.

2. The method of claim 1 , wherein the second layer of each of the plurality of alternating layers comprises a combination of aluminum oxide (Al 2 O 3 ), graphene, and silicon oxide.

3. The method of claim 2 , wherein the silicon oxide is treated with magnesia.

4. The method of claim 1 , wherein the one or more polymers of the first layer of each of the plurality of alternating layers comprises one or more conductive polymers.

5. The method of claim 4 , wherein the one or more conductive polymers comprise one or more thermoplastics, wherein the one or more thermoplastics comprise one or more of polyimide, polyethylene terephthalate (PET), poly(methylmethacrylate) (PMMA), or combinations thereof.

6. The method of claim 1 , wherein the multifunctional composite panel comprises the mandrel, and wherein the mandrel is integral with the plurality of structural layers.

7. The method of claim 1 , further comprising forming a surface protection layer adjacent the photovoltaic layers, wherein the surface protection layer comprises a combination of aluminum oxide and graphene.

8. The method of claim 1 , wherein forming the plurality of photovoltaic layers adjacent the plurality of structural layers comprises:
forming a third layer directly adjacent the structural layers, wherein the third layer comprises aluminum oxide, graphene, or any combination thereof;
forming a fourth layer directly adjacent the third layer, wherein the fourth layer comprises a conductive material; and
forming a fifth layer directly adjacent the fourth layer, wherein the fifth layer comprises one or more conductive polymers.

9. The method of claim 8 , wherein forming the plurality of photovoltaic layers adjacent the plurality of structural layers further comprises forming a sixth layer directly adjacent the fifth layer, wherein the sixth layer comprises graphene, aluminum oxide, or any combination thereof.

10. The method of claim 8 , wherein the conductive material of the fourth layer comprises graphene, indium tin oxide, or any combination thereof.

11. The method of claim 8 , wherein the one or more conductive polymers of the fifth layer comprise one or more of poly(3,4-ethylenedioxythiophene) (PEDOT), polystyrene sulfonate (PSS), PEDOT:PSS, polypyrroles (PPy), polyaniline (PANT), polyacetylene, polythiophene (PT), polyacetylene (PAC), poly p-phenylene vinylene (PPV), or any combination thereof.

12. A multifunctional composite panel, comprising:
a mandrel;
a plurality of structural layers disposed directly adjacent the mandrel, wherein the plurality of structural layers comprises a plurality of alternating layers, wherein:
each of the plurality of alternating layers comprises a first layer and a second layer, the second layer disposed directly adjacent the first layer,
a first layer of each of the plurality of alternating layers comprises one or more polymers, and
a second layer of each of the plurality of alternating layers comprises one or more of aluminum oxide (Al 2 O 3 ), graphene, silicon oxide, or combinations thereof; and

a plurality of photovoltaic layers disposed adjacent the plurality of structural layers, wherein the plurality of photovoltaic layers is configured to convert light energy into electrical power,
wherein the multifunctional composite panel has a thickness of from about 1 mm to about 30 mm.

13. The multifunctional composite panel of claim 12 , wherein:
the second layer of each of the plurality of alternating layers comprises a combination of aluminum oxide (Al 2 O 3 ), graphene, and silicon oxide; and
the one or more polymers comprise one or more thermoplastics, the one or more thermoplastics comprise one or more of polyimide, polyethylene terephthalate (PET), poly(methylmethacrylate) (PMMA), or combinations thereof.

14. The multifunctional composite panel of claim 12 , wherein the multifunctional composite panel comprises:
a transparency of from about 30% to about 95%, as measured by the transmissivity of light;
an in-plane specific stiffness of greater than or equal to 15.0E6 m 2 /s 2 ;
a thermal expansion coefficient in one or more directions of greater than or equal to about 0° K −1 , and less than or equal to about 50 E-6° K −1 ;
an in-plane specific strength (σx/ρ) of greater than or equal to about 150 kN·m/Kg; and
a density of from about 1.5 g/cm 3 to about 2.20 g/cm 3 .

15. The multifunctional composite panel of claim 12 , wherein the multifunctional composite panel is substantially free of structural fibers.

16. A method for fabricating a multifunctional composite panel, the method comprising:
depositing a plurality of structural layers directly on a mandrel, wherein depositing the plurality of structural layers on the mandrel comprises depositing a plurality of alternating layers directly on the mandrel, wherein each of the plurality of alternating layers comprises a first layer and a second layer, and wherein depositing the plurality of alternating layers comprises:
depositing a first layer of each of the plurality of alternating layers from one or more polymers, wherein the one or more polymers are selected from the group consisting of polyimide, polyethylene terephthalate (PET), poly(methylmethacrylate) (PMMA), and combinations thereof; and
depositing a second layer of each of the plurality of alternating layers directly adjacent the first layer of each of the plurality of alternating layers, wherein the second layer of each of the plurality of alternating layers comprises one or more of aluminum oxide (Al 2 O 3 ), graphene, silicon oxide, or combinations thereof;

depositing a plurality of photovoltaic layers directly adjacent the plurality of structural layers, wherein depositing the plurality of photovoltaic layers comprises:
depositing a first layer of the plurality of photovoltaic layers directly adjacent the plurality of structural layers, wherein the first layer of the plurality of photovoltaic layers comprises one or more of aluminum oxide, graphene, or combinations thereof;
depositing a second layer of the plurality of photovoltaic layers directly adjacent the first layer of the plurality of photovoltaic layers, wherein the second layer of the plurality of photovoltaic layers comprises one or more conductive materials selected from the group consisting of graphene, indium tin oxide, and combinations thereof; and
depositing a third layer of the plurality of photovoltaic layers directly adjacent the second layer of the plurality of photovoltaic layers, wherein the third layer of the plurality photov

Assignees

• Boeing Co

Inventors

• Cheng Jiangtian
• Nordman Paul S
• Yoon Hojun
• Zhang Xiaobo

Classifications

• H10K50/8445

  multilayered coatings having a repetitive structure, e.g. having multiple organic-inorganic bilayers · CPC title

• H10F19/80 Primary

  Encapsulations or containers for integrated devices, or assemblies of multiple devices, having photovoltaic cells · CPC title

• H10F77/211

  for photovoltaic cells · CPC title

• H10F77/30

  Coatings (arrangements for preventing damage to photovoltaic cells caused by corpuscular radiation H10F77/80) · CPC title

• H10F19/31

  having multiple laterally adjacent thin-film photovoltaic cells deposited on the same substrate · CPC title