Glass-free European photovoltaic modules for vehicles, noise barriers and boats

The European Sunrise consortium is developing glass-free photovoltaic modules by embedding solar cells directly into fiber-reinforced polymer composites, eliminating the need for traditional glass encapsulation. This approach enables the production of lightweight modules that can conform to curved or irregular surfaces, broadening applications for integrated photovoltaics. The project builds on prior validation by partners, including expertise in composite processing, lamination, and liquid composite molding, as well as techniques like laser cutting and texturing. Laboratory and outdoor tests have already shown a 50% reduction in total reflection on these surfaces.

The consortium has assigned specific roles to its 12 partners across eight European countries, with Spain’s Aimen leading laser-related developments, Germany’s Fraunhofer ISE focusing on lamination, and Sweden’s Sticky Solar Power creating a prototype string-manufacturing system. Italy’s Solbian will test this system, while Solitek and Forster System-Montage-Technik will adapt composite manufacturing processes for industrial use. The project, which began in June 2024, will run for 36 months and aims to establish an industrial platform for producing glass-free modules.

Three pilot facilities will specialize in different stages of production, distributing the manufacturing chain rather than concentrating it at a single site. The first demonstrator targets vehicle-integrated photovoltaics, aiming for an 80% weight reduction, 30% lower system costs, and a 50% reduction in lamination time. The second focuses on photovoltaic noise barriers, seeking a 30% weight reduction and 98% efficiency compared to TOPCon modules, while withstanding 5,400 Pa of static pressure.

The third demonstrator will develop continuous solar surfaces for ship decks with anti-slip properties, targeting over 20% cost reduction compared to conventional solutions. The project also prioritizes end-of-life considerations, including disassembly, repairability, and recycling, while ensuring compliance with applicable standards. However, scaling up will require overcoming challenges in reliability, compatibility with high-efficiency cell technologies, and certification under existing standards.