Thin solar panel lamination on fabric structures

Abstract

The goal of this thesis was to conceive of a new process for laminating thin solar panels onto fabric structures, then design, prototype, and test a device to facilitate this new process. Pvilion, a Brooklyn based company which creates large fabric tents and canopies outfitted with solar panels, currently employs a lamination method which is labor intensive, difficult to execute with precision, and prone to user error. The process developed from this thesis involves two pieces of machinery which first apply adhesive to the solar modules offsite, and then place the pre-taped solar modules onto fabric. Concepts for these two machines were thoroughly designed and tested, leading to the final proposed system. This newly developed process, with accompanying machinery, will allow Pvilion to produce solar panel clad structures at a greater rate of speed, with less labor, and with fewer user errors, ultimately improving the quality of their end products.