Abstract
An electricity-generating coating is provided for a surface of a cargo carrying vehicle. The electricity-generating coating includes a conformal organic photovoltaic device configured to be applied and conformed to the surface of the cargo carrying vehicle and configured to supply power for one or more electronic or electrical components or systems at least one of on-board or off-board the cargo carrying vehicle.
Claims
1. A cargo carrying vehicle designed to transport cargo on land to a destination, the cargo carrying vehicle comprising: an electrical system having one or more electrical components; a surface having an electricity-generating film coupled thereto, the electricity generating film comprising; a stack of layers for converting light into electrical energy, the stack of layers comprising a conformal organic photovoltaic device configured to convert light incident to the surface into electrical current, the stack of layers including at least one conducting layer configured to collect and transfer at least some of the electrical current to the electrical system, wherein the stack of layers is configured to be flexible to allow the film to conform to the surface so that the surface is aerodynamic, and wherein the stack of layers is configured to be transparent or semitransparent so as to allow at least a portion of the light incident to the surface to pass through the film.
2. The cargo carrying vehicle of claim 1, wherein the electricity-generating film is applied and conformed to the surface by coating the stack of layers onto the surface.
3. The cargo carrying vehicle of claim 2, wherein the electricity-generating film is coated directly onto the surface.
4. The cargo carrying vehicle of claim 3, wherein the electricity-generating film is coated directly onto the surface such that a topography of the electricity-generating film conforms to a topography of the surface.
5. The cargo carrying vehicle of claim 4, wherein the electricity-generating film is coated directly onto the surface without any space or entrapped air being present between the electricity-generating film and the surface such that the topography of the electricity-generating film directly conforms to the topography of the surface.
6. The cargo carrying vehicle of claim 1, wherein the electricity-generating film further comprises: a pressure-sensitive adhesive on the stack of layers, wherein the electricity-generating film is configured to be applied and conformed to the surface by adhering and conforming the pressure-sensitive adhesive onto the surface.
7. The cargo carrying vehicle of claim 6, wherein the pressure-sensitive adhesive is configured to be adhered and conformed directly onto the surface.
8. The cargo carrying vehicle of claim 6, wherein the pressure-sensitive adhesive is configured to be adhered and conformed directly onto the surface such that a topography of the electricity-generating film conforms to a topography of the surface.
9. The cargo carrying vehicle of claim 8, wherein the pressure-sensitive adhesive is configured to be adhered and conformed directly onto the surface without any space or entrapped air being present between the pressure-sensitive adhesive and the surface such that the topography of the electricity-generating film directly conforms to the topography of the surface.
10. The cargo carrying vehicle of claim 1, wherein a topography of the surface includes at least one planar surface.
11. The cargo carrying vehicle of claim 1, wherein a topography of the surface includes at least one curved surface.
12. The cargo carrying vehicle of claim 1, wherein a topography of the surface includes a combination of at least one planar surface and at least one curved surface.
13. The cargo carrying vehicle of claim 1, wherein the surface is a non-transparent surface.
14. The cargo carrying vehicle of claim 1, wherein the surface is one of a transparent surface and a semi-transparent surface.
15. (canceled)
16. The cargo carrying vehicle of claim 6, wherein the surface is one of a transparent surface and a semi-transparent surface, and wherein the electricity-generating film is configured such that at least a portion of the light incident to the surface is capable of passing through the stack of layers and the pressure-sensitive adhesive.
17. (canceled)
18. The cargo carrying vehicle of claim 6, wherein the stack of layers is flexible and the pressure-sensitive adhesive is flexible.
19. The cargo carrying vehicle of claim 1, wherein the surface is an exterior surface of a component of the cargo carrying vehicle.
20. The cargo carrying vehicle of claim 1, wherein the surface is an interior surface of a component of the cargo carrying vehicle.
21. The cargo carrying vehicle of claim 1, wherein the electricity-generating coating is configured to supply power for the one or more electrical components of the electrical system.
22. The cargo carrying vehicle of claim 19, wherein a leading edge of the electricity-generating film is concealed behind a second exterior surface of the cargo carrying vehicle.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0048] These and other aspects and features of embodiments of the present invention will be better understood after a reading of the following detailed description, together with the attached drawings, wherein:
[0049] FIG. 1 is a schematic illustration of a cargo carrying vehicle having an electricity-generating coating according to exemplary embodiments of the invention;
[0050] FIG. 2 is a schematic illustration of a cargo carrying vehicle having an electricity-generating coating according to exemplary embodiments of the invention;
[0051] FIG. 3 is a schematic illustration of a cargo carrying vehicle having an electricity-generating coating according to exemplary embodiments of the invention;
[0052] FIG. 4 is a schematic illustration of a cargo carrying vehicle having an electricity-generating coating according to exemplary embodiments of the invention;
[0053] FIG. 5 is a schematic illustration of a cargo carrying vehicle having an electricity-generating coating according to exemplary embodiments of the invention;
[0054] FIG. 6 is a cross-sectional view of a pressure-sensitive adhesive-coated organic photovoltaic device, itself coated on a thin flexible substrate with a transfer release layer and rigid backing layer, which can be used to prepare planar and curved organic photovoltaic device-covered surface of a cargo carrying vehicle, according to an exemplary embodiment of this invention.
[0055] FIG. 7 is a cross-sectional view of an organic photovoltaic device coated onto a planar surface of a cargo carrying vehicle using the pressure-sensitive adhesive method according to an exemplary embodiment of the invention.
[0056] FIG. 8 is a cross-sectional view of an organic photovoltaic device coated onto a curved surface of a cargo carrying vehicle using the pressure-sensitive adhesive method according to an exemplary embodiment of the invention.
[0057] FIG. 9 is a cross-sectional view of an organic photovoltaic device coated directly onto a planar surface of a cargo carrying vehicle using conventional coating methods according to an exemplary embodiment of the invention.
[0058] FIG. 10 is a cross-sectional view of an organic photovoltaic device coated directly onto a curved surface of a cargo carrying vehicle using conventional coating methods according to an exemplary embodiment of the invention.
[0059] FIG. 11 is a cross-sectional view of a pressure-sensitive adhesive-coated, semitransparent organic photovoltaic device, itself coated on a thin flexible substrate with a transfer release layer and rigid backing layer, which can be used to prepare a planar and curved organic photovoltaic device-covered window of a cargo carrying vehicle, according to an exemplary embodiment of this invention.
[0060] FIG. 12 is a cross-sectional view of a semitransparent organic photovoltaic device coated onto a window of a cargo carrying vehicle using the pressure-sensitive adhesive method according to an exemplary embodiment of the invention.
[0061] FIG. 13 is a cross-sectional view of a semitransparent organic photovoltaic device coated directly onto a planar window windows of a cargo carrying vehicle using conventional coating methods according to an exemplary embodiment of the invention.
[0062] FIG. 14 is a cross-sectional view of a semitransparent organic photovoltaic device coated onto a curved window windows of a cargo carrying vehicle using the pressure-sensitive adhesive method according to an exemplary embodiment of the invention.
[0063] FIG. 15 is a cross-sectional view of a semitransparent organic photovoltaic device coated directly onto a curved window windows of a cargo carrying vehicle using conventional coating methods according to an exemplary embodiment of the invention.
DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS OF THE INVENTION
[0064] The present invention now is described more fully hereinafter with reference to the accompanying drawings, in which embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.
[0065] Referring now to the drawings, FIGS. 1-15 illustrate exemplary embodiments of electricity-generating coatings 100 for a cargo carrying vehicle 10. As explained in greater detail below, exemplary embodiments of the electricity-generating coating 100 can comprise a conformal organic photovoltaic device (e.g., a flexible conformal organic photovoltaic device), including one or more cells connected in series and/or parallel, wherein the conformal organic photovoltaic device is configured to be applied and conformed to a surface of the cargo carrying vehicle 10 and configured to supply power for one or more electronic or electrical components or systems on-board and/or off-board of the cargo carrying vehicle 10; and a pressure-sensitive adhesive on the flexible conformal organic photovoltaic device, the pressure-sensitive adhesive being flexible and configured to adhere and conform the flexible conformal organic photovoltaic device to the surface of the cargo carrying vehicle 10.
[0066] As explained, a “cargo carrying vehicle” is defined as a vehicle capable of carrying or transporting goods, materials, cargo, equipment, freight, people, troops, and/or other vehicles, etc., among other items, from one location to another, and is not limited to any particular vehicle. Such a cargo carrying vehicle can include a vehicle propelled by one or more motive means, such as a motorized vehicle (e.g., fossil fuel powered vehicle), an electric vehicle, a magnetically propelled vehicle, a hydrogen-powered vehicle, a wind-powered vehicle, a propeller, turbine, or jet engine powered vehicle, and/or an ambulatory powered vehicle, etc., among other types of vehicles, a vehicle configured for operation on various roadway surfaces, off-road operation, water operation, air operation, rail operation, stationary or floating platform operation, etc., a vehicle configured for military use or civilian use, including for example commercial use, private use, municipal or government use, use by armed services, law enforcement, or other organizations, etc. In other examples, a cargo carrying vehicle can include other vehicles or transports, such as construction, mining, or building equipment, such as mining, drilling, excavating, and/or earthmoving equipment, lifting equipment for lifting and/or moving, etc., a railway vehicle such as a monorail or a train including cargo, passenger, and/or commuter railway vehicles, etc. such as motorized railway vehicles, electric railway vehicles, magnetic railway vehicles, etc., a water vessel including a cargo, passenger, and/or commuter water vessel, etc. configured for military use or civilian use, including for example commercial use, private use, municipal or government use, use by armed services, coast guard, law enforcement, or other organizations, etc., including a motorized water vessel, an electric water vessel, and/or a wind-powered vessel, etc., such as a yacht, fishing boat, recreation watercraft, sailboat, armed services watercraft, lifesaving/lifeguard watercraft, etc. among other things, or other vehicles such as so-called people movers, for example, for use in airports, amusement parks etc.
[0067] With reference to FIGS. 1-5, an exemplary embodiment of a cargo carrying vehicle 10 will be described reference to a semi-tractor-trailer truck. One of ordinary skill in the art will recognize that the semi-tractor-trailer truck illustrated is for exemplary purposes, and is not intended to limit the invention to any particular example of, or part of, a cargo carrying vehicle.
[0068] As shown in FIGS. 1-5, a cargo carrying vehicle 10, such as a semi-tractor-trailer truck, can include a tractor 20 having a cab 22 or a sleeper cab 30 with a variety of exterior surfaces configured to improve aerodynamic characteristics of the vehicle 10
[0069] The tractor 20 can include a variety of exterior surfaces configured to improve aerodynamic characteristics of the vehicle 10, provide sufficient space within the vehicle 10 for one or more vehicle operators to rest or sleep during idle times, etc. The exterior surfaces can include non-transparent surfaces formed from steel, aluminum, plastic, fiberglass, thermoplastic, etc. The exterior surfaces of the cab 22 can include, for example, a front/grille, fenders 24, a hood/engine compartment cover 26, sides, rear, roof 28, doors, sleeper cab 30, bumper 32, mirrors, one or more side fairings, including fuel tank side fairings 34, storage side fairings 36, storage compartments 38, etc., a cab roof fairing 40, a cab roof wind deflector 42, and/or cab-mounted gap reducers 44, etc. The exterior surfaces of the cab 22 can include, for example, a variety of transparent surfaces such as one or more cab or sleeper side windows 46, sky lights, moon roofs, etc.
[0070] In an example in which the surface of the vehicle is a transparent surface, such as one or more cab or sleeper side windows 46, sky lights, moon roofs, etc., the conformal organic photovoltaic device can be semitransparent and a pressure-sensitive adhesive also can be one of semitransparent and transparent such that light is capable of passing through the conformal organic photovoltaic device and the pressure-sensitive adhesive of the electricity-generating coating from either side, thereby permitting visibility through the transparent surface of the vehicle 10 from within an interior of the vehicle 10 and/or from outside the vehicle 10.
[0071] With reference again to FIGS. 1-5, in some examples, a cargo carrying vehicle 10 also may include a trailer 50 having a variety of surfaces configured to provide sufficient space within the trailer 50 for securing cargo/freight, improving aerodynamic characteristics of the trailer, etc. For example, the trailer 50 can include one or more non-transparent surfaces such as front, side 52, rear, and/or roof 54 surfaces, side fairings 56, rear fairings or boat-tail 58, trailer-mounted gap reducers 60, and/or a trailer air conditioning unit(s) 62.
[0072] Some surfaces of the tractor 20 and trailer 50 can be planar, while other surfaces can be curved (e.g., non-planar in one or more dimensions).
[0073] With reference to FIGS. 4 and 5, one or more electricity-generating coatings 100 can be applied and conformed (e.g., coated or adhered) to one or more surfaces of the vehicle 10. The one or more electricity-generating coatings 100 can comprise a conformal organic photovoltaic device (e.g., flexible coating or adhesive device), including one or tore cells connected in series and/or parallel, wherein the conformal organic photovoltaic device is configured to be applied and conformed (e.g., coated or adhered) to a surface of the cargo carrying vehicle 10 and configured to supply power for one or more electronic or electrical components or systems 600, for example, of the cargo carrying vehicle 10. The surfaces illustrated as having electricity-generating coatings 100 are for example purposes only and the embodiments are not limited to any particular surface or combination of surfaces.
[0074] As shown in FIG. 4, the tractor 20 can include one or more electricity-generating coatings 100 configured for providing power to one or more electronic or electrical components or systems 600 of the tractor 20. For example, one or more electricity-generating coatings 100 can be configured for charging (re-charging) and/or supplying power to one or more batteries of the tractor, for providing power for operation of one or more electronic components of the tractor, such as exterior lighting on the tractor (e.g. marker lights), interior lighting, audio/video unit(s), heating/air conditioning systems, electronics charging ports, etc. in the cab. One or more electrical connections 610 can be provided to connect the one or more electricity-generating coatings 100 configured for providing power to one or more electronic or electrical components or systems 600 of the tractor 20.
[0075] As shown in FIG. 4, the tractor 20 and/or the trailer 50 can include one or more electricity-generating coatings 100 configured for providing power to one or more electronic or electrical components or systems 600 of the tractor 20 and/or one or more electronic or electrical components or systems 620 of the trailer 50. For example, one or more electricity-generating coatings 100 can be configured for charging (re-charging) and/or supplying power to one or more batteries of the trailer 50, for providing power for operation of one or more electronic components of the trailer 50, such as exterior lighting on the trailer (e.g. marker lights), interior lighting within the cargo area of the trailer 50, heating/air conditioning systems 62 on the trailer 50, etc. One or more electrical connections 610 can be provided to connect the one or more electricity-generating coatings 100 configured for providing power to one or more electronic or electrical components or systems 600 of the tractor 20 and/or the trailer 50.
[0076] In an example, the electricity-generating coating 100 can include a conformal organic photovoltaic device configured to be applied and conformed to the surface of the cargo carrying vehicle 10 by coating the conformal organic photovoltaic device onto the surface of the cargo carrying vehicle 10. In another example, the electricity-generating coating 100 can include a pressure-sensitive adhesive on the conformal organic photovoltaic device, wherein the conformal organic photovoltaic device is configured to be applied and conformed to the surface of the cargo carrying vehicle 10 by adhering and conforming the pressure-sensitive adhesive of the conformal organic photovoltaic device onto the surface of the cargo carrying vehicle 10.
[0077] With reference to FIGS. 6-15, exemplary embodiments of an electricity-generating coating 100 for a cargo carrying vehicle 10 will now be described. Similar reference numerals are used for similar features of the exemplary embodiments.
[0078] FIG. 6 provides a cross-sectional view of an intermediate film stack produced for the eventual fabrication of electricity-generating coatings for surfaces of a cargo carrying vehicle 10. The exemplary film is prepared upon a temporary base layer 101, in order to provide sufficient rigidity to allow conventional manufacturing techniques, including high-speed roll-to-roll coating. The base layer 101 can include of thick polymer foils, metal foils, glass substrates, or any convenient substrate material, depending on the chosen manufacturing methods. On top of the base layer 101 is a transfer release layer 102 that allows easy removal of the base layer 101 and transfer release layer 102 from the thin flexible substrate 103, which are all laminated together as known to those skilled in the art. The thin flexible substrate 103 is any appropriate substrate material that is highly flexible and transparent, such as very thin polymer foils, including but not limited to polyethyleneterephthalate (PET). On top of the thin flexible substrate 103 is coated an electricity-generating coating device 104, comprising one or more cells connected in series and/or parallel, which is inherently flexible and thus contains no highly crystalline materials. The multi-layered electricity-generating coating device 104 is coated and processed according to standard methods known to those skilled in the art, such as slot-die coating and laser scribing, which are compatible with high-throughput manufacturing techniques, including high-speed roll-to-roll or sheet-to-sheet production methods. Finally, the electricity-generating coating device 104 is coated on top (on an exterior facing side when adhered to a surface of the vehicle 10) with a semitransparent pressure-sensitive adhesive 105 according to methods know to those skilled in the art. The resulting film comprising layers 101-105 can be used to transfer the electricity-generating coating device comprising layers 103-105 onto a surface of the cargo carrying vehicle 10 to the surface into an electricity-generating surface.
[0079] Referring to FIG. 7, which provides a cross-sectional view of a planar surface 206 of a cargo carrying vehicle 10 having an electricity-generating coating 100 produced via a pressure-sensitive adhesive method. In this example, a base layer 206 includes a planar surface of the cargo carrying vehicle 10. The electricity-generating device 204 is laminated onto the planar surface 206 of the cargo carrying vehicle 10 using stretching and press-forming, with or without vacuum assistance in removing entrained air. The electricity-generating coating device 204 is adhered to the planar surface 206 of the cargo carrying vehicle 10 using a pressure-sensitive adhesive layer 205, and is supported by the thin flexible substrate layer 203. Finally, the whole device 204 can be protected via a clear hard-coat 207 (e.g., a clear epoxy), which can be applied via a variety of techniques known to those skilled in the art, such as spray coating. While, in this exemplary embodiment, the method is necessarily a discrete object process for the fabrication of each individual surface 206 of the cargo carrying vehicle 10, the intermediate transfer film (see FIG. 6) used to transfer the completed electricity-generating coating device onto the planar surface 206 of the cargo carrying vehicle 10 can be produced in a continuous, high-throughput methodology. Not shown are any wires or other electrical contacts, or any power circuitry (e.g., inverters), which would be contained largely within the tractor 20 or trailer 50 of the cargo carrying vehicle 10.
[0080] Referring to FIG. 8, which provides a cross-sectional view of a curved surface 306 of the cargo carrying vehicle 10 having an electricity-generating coating 100 produced via a pressure-sensitive adhesive method. The base layer 306 includes a curved surface 306 of a cargo carrying vehicle 10. The electricity-generating coating device 304 is laminated onto the curved surface 306 of the cargo carrying vehicle 10 using stretching and press-forming, with or without vacuum assistance in removing entrained air. The electricity-generating coating device 304 can be adhered to the curved surface 306 of the cargo carrying vehicle 10 using the pressure-sensitive adhesive layer 305, and is supported by the thin flexible substrate layer 303. Finally, the whole electricity-generating coating device 304 is protected via a clear hard-coat 307 (e.g., a clear epoxy), which can be applied via a variety of techniques known to those skilled in the art, such as spray coating. The unique and inherent flexibility of electricity-generating coating devices 100 allows lamination onto curved surfaces 306 of the cargo carrying vehicle 10 while minimizing or reducing disruption of device performance, and enables production of an electricity-generating coating device 100 that can be applied to cover or conform to a topography of all or a portion of various surfaces, with a variety of topographies, of a cargo carrying vehicle 10, which may be difficult to achieve via conventional coating techniques. For example, the exemplary devices and methods can enable electricity-generating coating devices 100 to be laminated onto curved surface 306 of the cargo carrying vehicle 10 of arbitrary and changing curvature (e.g., arbitrary or changing topography). While, in this exemplary embodiment, the method may be a discrete object process for the fabrication of each individual surface 306 of the cargo carrying vehicle 10, the intermediate transfer film (see FIG. 6) used to transfer the completed electricity-generating coating device 100 onto the curved surface 306 of the cargo carrying vehicle 10 can be produced in a continuous, high-throughput methodology. Not shown are any wires or other electrical contacts, or any power circuitry (e.g. inverters), which would be contained largely within the cargo carrying vehicle 10.
[0081] Referring to FIG. 9, which provides a cross-sectional view of a planar surface 406 of the cargo carrying vehicle 10 having an electricity-generating coating 100 produced via the conventional coating method, the base layer includes a planar surface 406 of the cargo carrying vehicle 10. First, the planar surface 406 of the cargo carrying vehicle 10 is coated with an insulating layer 408 using methods known to those skilled in the art, to allow isolation of the individual cells from each other and from the surface 406 of the cargo carrying vehicle 10, preventing electrification of the entire surface 406 or other components of the cargo carrying vehicle 10. The electricity-generating coating device 404 is then coated onto the insulating layer 408 using conventional coating techniques such as known to those skilled in the art. Finally, the whole electricity-generating coating device 404, 408 is protected via a clear hard-coat 407 (e.g., a clear epoxy), which can be applied via a variety of techniques known to those skilled in the art, such as spray coating. While this method has the advantage of having less extraneous layers and materials involved as compared to the laminated processes (see FIG. 7), in this exemplary embodiment, the method can include a sheet-to-sheet coating process performed on a surface-by-surface basis for every individual layer in the electricity-generating coating device, which can limit throughput and increase defects, compared to producing the electricity-generating coating device in a continuous process (see FIG. 6). Not shown are any wires or other electrical contacts, or any power circuitry (e.g. inverters), which would be contained largely within the cargo carrying vehicle 10.
[0082] Referring to FIG. 10, which provides a cross-sectional view of a curved surface 506 of the cargo carrying vehicle 10 having an electricity-generating coating 100 produced via the conventional coating method, the base layer includes a curved surface 506 of the cargo carrying vehicle 10. First, the curved surface 506 of the cargo carrying vehicle 10 is coated with an insulating layer 508 using methods known to those skilled in the art, to allow isolation of the individual cells from each other and from the curved surface 506 of the cargo carrying vehicle 10, preventing electrification of the entire curved surface 506 or other components of the cargo carrying vehicle 10. The electricity-generating coating device 504 is then coated onto the insulating layer 508 using conventional coating techniques such as spray or curtain coating. Finally, the whole electricity-generating coating device 504, 508 is protected via a clear hard-coat 507 (e.g., a clear epoxy), which can be applied via a variety of techniques known to those skilled in the art, such as spray coating. As such, the pressure-sensitive adhesive lamination method presents an attractive alternative for the production of curved surfaces 506 of a cargo carrying vehicle 10 (see FIG. 8).
[0083] Referring now to the drawings, FIGS. 11-15 illustrate exemplary embodiments of electricity-generating coatings for a window surface and methods for manufacture thereof.
[0084] Referring to FIG. 11, which provides a cross-sectional view of an intermediate film stack produced for the eventual fabrication of electricity-generating coatings for window surfaces of a cargo carrying vehicle 10, the film or coating is prepared upon a temporary base layer 101, in order to provide sufficient rigidity to allow conventional manufacturing techniques, including high-speed roll-to-roll coating. The base layer 101 can include thick polymer foils, metal foils, or any convenient substrate material, depending on the chosen manufacturing methods. On top of the base layer 101 s a transfer release layer 102 that allows easy removal of the base layer 101 and transfer layer 102 from the thin flexible substrate 103, which are all laminated together as known to those skilled in the art.
[0085] The thin flexible substrate 103 is any appropriate substrate material that is highly flexible and transparent, such as very thin polymer foils, including but not limited to polyethyleneterephthalate (PET). On top of the thin flexible substrate 103 is coated a semi-transparent electricity-generating coating device 104, comprising one or more cells connected in series and/or parallel, which is inherently flexible and thus contains no highly crystalline materials. The multi-layered electricity-generating coating device 104 is coated and processed according to standard methods known to those skilled in the art, such as slot-die coating and laser scribing, which are compatible with high-throughput manufacturing techniques, including high-speed roll-to-roll or sheet-to-sheet production methods. Finally, the electricity-generating coating device 104 is coated on top with a semitransparent pressure-sensitive adhesive 105 according to methods know to those skilled in the art. The resulting film comprising layers 101-105 can be used to transfer the semitransparent electricity-generating coating device comprising layers 103-105 onto a window surface of a cargo carrying vehicle 10 to convert the window into electricity-generating window surface.
[0086] Referring to FIG. 12, which provides a cross-sectional view of a planar window surface of a cargo carrying vehicle 10 having an electricity generating coating 100 produced via the pressure-sensitive adhesive method, the base layer 206 comprises a planar window of a cargo carrying vehicle 10. The electricity-generating semitransparent electricity-generating coating device 204 is laminated onto the window 206 using stretching and press-forming, with or without vacuum assistance in removing entrained air. The electricity-generating semitransparent electricity-generating coating device 204, which is adhered to the window using the pressure-sensitive adhesive layer 205, and is supported by the thin flexible substrate layer 203. While, in this exemplary embodiment, the method is necessarily a discrete object process for the fabrication of each individual window, the intermediate transfer film (see FIG. 11) used to transfer the completed electricity-generating coating device onto the window can be produced in a continuous, high-throughput methodology. Not shown are any wires or other electrical contacts, or any power circuitry (e.g. inverters), which would be contained within the window casing or body of the cargo carrying vehicle 10, respectively, or any protective coatings that might be desirable.
[0087] Referring to FIG. 13, which provides a cross-sectional view of a planar window of a cargo carrying vehicle 10, an electricity-generating coating 100 produced via the conventional coating method, the base layer 306 includes a planar window of a cargo carrying vehicle 10. The semitransparent electricity-generating coating device 304 is coated directly onto the window surface using conventional coating techniques such as known to those skilled in the art. While this method has the advantage of having less extraneous layers and materials involved as compared to the laminated processes (see FIG. 12), in this exemplary embodiment, it is necessarily a sheet-to-sheet coating process performed on a window-by-window basis for every individual layer in the electricity-generating coating device, which can limit throughput and increase defects, compared to producing the electricity-generating coating device in a continuous process (see FIG. 1). Not shown are any wires or other electrical contacts, or any power circuitry (e.g. inverters), which would be contained within the window casing or body of the cargo carrying vehicle 10, respectively, or any protective coatings that might be desirable. In the example shown in FIG. 13, the whole electricity-generating coating device 304 can be protected via a clear hard-coat (e.g., a clear epoxy), which can be applied via a variety of techniques known to those skilled in the art, such as spray coating.
[0088] Referring to FIG. 14, which provides a cross-sectional view of a curved window 406 of a cargo carrying vehicle 10, an electricity-generating coating 100 produced via the pressure-sensitive adhesive method, the base layer 406 comprises a curved window 406 of a cargo carrying vehicle 10. The electricity-generating semitransparent electricity-generating coating device 404 is laminated onto the curved window 406 of a cargo carrying vehicle 10 using stretching and press-forming, with or without vacuum assistance in removing entrained air, is the electricity-generating semitransparent electricity-generating coating device 404, which is adhered to the window using the pressure-sensitive adhesive layer 405, and is supported by the thin flexible substrate layer 403. The unique and inherent flexibility of electricity-generating coating devices allows lamination onto curved surfaces (e.g., curved topography) without significant disruption of device performance, and enables production of electricity-generating coating devices applied and conformed to various topographies of surfaces of a cargo carrying vehicle that would be difficult to produce via conventional coating techniques due to realities of capillarity flow on curved surfaces. For example, the exemplary devices and methods enable electricity-generating coating devices to be laminated onto a curved window 406 of a cargo carrying vehicle 10 of arbitrary and changing curvature (e.g., varying topography, including planar, curved, or combinations thereof). While, in this exemplary embodiment, the method is necessarily a discrete object process for the fabrication of each individual window, the intermediate transfer film (see FIG. 11) used to transfer the completed electricity-generating coating device onto the window can be produced in a continuous, high-throughput methodology. Not shown are any wires or other electrical contacts, or any power circuitry (e.g., inverters), which would be contained within the window casing or body of a cargo carrying vehicle 10, respectively, or any protective coatings that might be desirable. In the example shown in FIG. 14, the whole electricity-generating coating device can be protected via a clear hard-coat (e.g., a clear epoxy), which can be applied via a variety of techniques known to those skilled in the art, such as spray coating.
[0089] Referring to FIG. 15, which provides a cross-sectional view of a curved window 406 of a cargo carrying vehicle 10, the electricity generating coating 100 produced via the conventional coating method. The semitransparent electricity-generating coating device 504 is coated directly onto the window surface using conventional coating techniques such as spray or curtain coating. As such, the pressure-sensitive adhesive lamination method presents an attractive alternative for the production of curved window 406 of a cargo carrying vehicle 10 (see FIG. 14). In the example shown in FIG. 15, the whole electricity-generating coating device can be protected via a clear hard-coat (e.g., a clear epoxy), which can be applied via a variety of techniques known to those skilled in the art, such as spray coating.
[0090] The present invention has been described herein in terms of several preferred embodiments. However, modifications and additions to these embodiments will become apparent to those of ordinary skill in the art upon a reading of the foregoing description. It is intended that all such modifications and additions comprise a part of the present invention to the extent that they fall within the scope of the several claims appended hereto.
