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Tesla patent hints at stunning colored Solar Roof tiles with zero compromises

[Credit: Tesla]

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Elon Musk recently noted on Twitter that Tesla would be prioritizing the production of its Solar Roof tiles this coming 2019. These updates were announced not long after the company invited local media from Buffalo, NY to tour Gigafactory 2, the company’s facility which is producing the unique solar shingles. As Tesla continues to prepare for the ramp of the Solar Roof tiles next year, a recent patent has been published outlining a design that would allow the company to offer colored variants of the solar shingles without compromising any functionality.

Tesla’s recent patent, titled “Uniformly and Directionally Colored Photovoltaic Modules,” was published last Thursday. In the document’s background, Tesla noted that PV modules are usually blue, dark blue, or black because these are the natural color of solar cells. Considering that homeowners have preferences in their roofing material’s color, though, there is a need for the Solar Roof tiles to have varying shades and textures. There are currently several conventional ways to colorize PV modules, such the utilization of tinted glass and/or encapsulation sheets. That said, such systems are prone to absorbing large amounts of sunlight, which results in PV power loss. The appearance of standard colored PV modules also tends to degrade over time.

“Shading, or absorption of incident sunlight, causes PV power loss, a consequential problem of existing coloring techniques. In addition, colored PV modules manufactured with these techniques, and colored glass more generally, commonly suffer from: sparkle, or glint; flop, or angle-dependent color appearance; and graininess. Note that sparkle refers to glint or localized bright spots. Flop, on the other hand, usually refers to angle-dependent color, i.e. an angular dependence of the peak reflected wavelength. The term flop, or light-dark flop, can also refer to angle-dependent brightness, i.e. an angular dependence of total reflectivity.”

An illustration of Tesla’s patent for its colored Solar Roof tiles. [Credit: US Patent Office]

Tesla’s system for its colored Solar Roof tiles utilizes a rather clever system to avoid the drawbacks of conventional PV module coloration methods. Instead of using traditional solutions like tinted glass, Tesla’s design employs a texturized surface of a glass cover that has a color filter layer, as well as a “transparent material with a predetermined refractive index.” Following is Tesla’s description of its colored Solar Roof tiles’ design.

“Embodiments of the present invention can produce PV roof tiles with a uniform color with little light absorption. As a result, a high proportion of the incident light (of colors other than the module’s intended color) is transmitted to the PV cells. To facilitate uniform coloring of PV modules and roof tiles, the inside surface of a top glass cover can be texturized, and a transparent material with a predetermined refractive index or combination of refractive indices can be deposited on the texturized surface. Such a micro-textured or frosted glass cover can display significantly less sparkle, flop, and graininess than conventional glass covers, thus improving color uniformity and appearance. Customizable directional coloring, and intentionally controlled angle-dependent color, can provide further aesthetic options, while still performing efficiently for solar conversion. It is also possible to produce a layer of sphere-shaped metal nanoparticles on the inside surface of the glass cover.

“These nanoparticles can produce colors efficiently while absorbing little light. Another feature described herein is directional coloring of PV modules or roof tiles. The texturized surface of a glass cover can have a color filter layer covering one or more facets of the texture. This color filter can include multiple thin film layers formed using a directional thin film deposition technique, such as chemical or physical vapor deposition (CVD or PVD), e.g. sputtering. The coating layer can be deposited by coating the textured glass surface in one or more directions. Such directional coating can reduce unwanted light absorption by the color filter, while still providing a uniform color appearance to viewers at a certain viewing angle.”

Tesla opted to design the colored Solar Roof tiles with textured “micro-structured” glass, which feature surface roughness on the order of 100 nm to 10 μιη. This allows the colored Solar Roof tiles to display a uniform color with little light absorption and less sparkle, flop, and graininess than conventional colored glass. The colored shingles’ design also provides customizable directional and multi-directional coating, improving the aesthetics of the Solar Roof tiles themselves while still being optimized for solar conversion.  

Following is a comparison of conventional colored PV modules (504 and 508) and Tesla’s coloration system (502 and 506), showing how the electric car maker’s micro-structured glass design addresses sparkle, or glare; flop, or angle-dependent coloring. 

A comparison of micro-textured uniformly colored glass to conventional glass. [Credit: US Patent Office]

The Solar Roof tiles are Tesla’s flagship residential solar product. Designed to mimic the appearance of conventional roofing materials while offering all the advantages of solar panels, the Solar Roofs are an excellent way for homeowners to utilize a PV system without compromising the aesthetics of their home. The shingles were warmly received when they were unveiled back in 2016, though the production and installation of Solar Roof tiles are yet to ramp. Elon Musk explained the delay in the shingles’ production ramp during the third quarter earnings call.

“We’ll also start going into volume production of the solar tile roof next year. That’s quite a long development cycle for — because anything that’s roof has got to last 30 years. So even if you do accelerate life testing as fast as possible, there’s still a minimum amount of time required to do that. And there’s a lot of engineering that goes into how do you put on the solar tile roof with a — and not be really labor-intensive in doing so. So there’s a lot of engineering not just in the tile but in the way it’s done,” Musk said.

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Back in July, Tesla CTO JB Straubel noted that the company is “aggressively” ramping its capacity to produce and deliver its residential solar products, stating that “No one should see us as stepping back from solar. In fact, it’s the opposite. It’s like with Model 3. People have come flooding in and are waiting on the product. So now we’re aggressively ramping our capacity.”  

The full text of Tesla’s patent for its colored Solar Roof tiles could be accessed here.

Simon is an experienced automotive reporter with a passion for electric cars and clean energy. Fascinated by the world envisioned by Elon Musk, he hopes to make it to Mars (at least as a tourist) someday. For stories or tips--or even to just say a simple hello--send a message to his email, simon@teslarati.com or his handle on X, @ResidentSponge.

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Energy

Tesla Semi factory is getting a celebration nobody expected

Tesla will inaugurate its Nevada Semi factory September 24, five months after production quietly began ramping.

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Tesla says it will officially inaugurate its new Semi factory in Nevada next month. The Tesla Semi account posted the announcement on X, sharing a graphic titled “Semi Rollout” with a date of September 24. No further details were given about the format of the event or who would attend.

While Tesla’s dedicated Semi plant in Sparks, adjacent to Gigafactory Nevada, opened back in April, with the first trucks rolling off the high volume line on April 29, the timing for the factory inauguration comes at a surprise. The ribbon cutting event five months into production is a break from how Tesla has usually handled its other factories, where the first truck or car off the line typically served as the milestone moment.

The 1.7 million square foot factory was built as part of a $3.6 billion expansion Tesla announced in early 2023, and it shares a site with the battery cell lines that feed the Semi’s structural pack, a decision meant to remove the supply bottleneck that delayed the truck for years. The plant is designed for 50,000 trucks a year at full ramp. Semi program director Dan Priestley has said production “is now ramping” rather than claiming it has reached scale.

Nine years passed between the Semi’s 2017 unveiling and this stage of production, with the truck slipping from an original 2019 target through hand built pilot units for PepsiCo and a slow build out of the Nevada plant. An inauguration event now gives Tesla a stage to talk up that ramp and reset expectations for how many trucks it can begin delivering at scale.

The September date also lines up with the Semi’s next milestone. Tesla confirmed the truck is heading to Europe with a full unveiling at the IAA Transportation trade show in Hannover, Germany, running September 15 through 20. Between the Nevada event and the Hannover reveal, Tesla has roughly a week and a half in September to make the case that the Semi is now a truck being built and sold on two continents rather than tested in a handful of fleets.

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Energy

Tesla launches Powerwall Lease for affordable home backup

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Credit: Tesla

Tesla Energy has introduced the Powerwall Lease in conjunction with Tesla Electric, making the service available in Texas. This new option delivers whole-home backup power using two Powerwall units for a net monthly cost of $35 after credits, accompanied by a low fixed electricity rate.

Under the lease terms, customers pay a one-time order fee of $100. The base lease payment for the two Powerwalls is approximately $122 per month during the first year, subject to a 3 percent annual escalator thereafter. Enrollment in a qualifying Tesla Electric Backup plan or Virtual Power Plant plan provides an $87 monthly credit.

This credit lowers the effective cost to roughly $35 per month plus applicable tax.

Installation of the standard system carries no additional charge. The package features Storm Watch for outage protection and allows complete management through a single Tesla application. The system supplies continuous whole-home backup capability.

The Powerwall system enables households to maintain electricity during severe storms that disrupt the utility grid. When outages occur, the batteries automatically provide seamless backup power to the home.

Tesla announces 100k Powerwalls are participating in Virtual Power Plants

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Tesla Storm Watch monitors weather forecasts and ensures the units are fully charged ahead of anticipated severe weather events so that power remains available throughout the disruption, keeping lights, refrigeration, and other essential systems operating without interruption.

Availability is restricted to select Texas locations where retail electric choice exists. Participants must lease exactly two Powerwall units and maintain continuous enrollment with Tesla Electric. Solar panels cannot be included under this particular lease arrangement.

The monthly credit activates automatically once the system is installed, receives permission to operate, and enrollment is confirmed. To retain the credit, customers are required to stay enrolled in Tesla Electric and fulfill all program conditions.

Nonstandard installations that involve electrical upgrades or special permitting may lead to extra expenses and might impact eligibility for the credit, so be sure to check with either your installer or Tesla to ensure you will still qualify.

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Elon Musk

Inside Tesla’s secretive $10 Billion “Project Crystal Sun” filing

Tesla filed for a $10.1 billion Fort Bend solar factory, but the site isn’t confirmed.

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Tesla has filed paperwork in Texas for a second massive manufacturing project in the same week it locked down its chip fabrication site, this time for a $10.1 billion solar cell plant in Fort Bend County. The filing, submitted July 22 under the state’s Jobs, Energy, Technology and Innovation Act and first surfaced by Sawyer Merritt on X, lists an internal project name of “Project Crystal Sun” and targets a site off FM 762 and FM 1994 near Richmond, about 40 minutes outside Houston.

The application, prepared by Kroll Tax Services on Tesla’s behalf, spans five parcels totaling roughly 3,000 acres within the Lamar Consolidated Independent School District. Tesla wants a 10 year property tax limitation in exchange for the investment, split as $1.5 billion in real property and $8.6 billion in equipment and personal property. The company projects 9,712 permanent jobs once the plant reaches full operation, with 1,147 peak construction jobs during a build window running from this year through 2028 and commercial operations targeted for the first quarter of 2029.

Tesla is not fully committed to Fort Bend County yet. The filing states the company is weighing the site against an unnamed out of state alternative, and frames the tax abatement as what would make Texas competitive against that option. If the district and county decline the incentive, Tesla says it may build elsewhere.

Tesla Megapack Megafactory in Texas advances with major property sale

The plant would handle the full solar cell production chain in one facility, according to the filing, covering wafer and ingot manufacturing, coating, metallization and printing lines, cell testing, automated material handling and cleanroom infrastructure. That scope points to Tesla vertically integrating a part of its supply chain it currently sources largely from overseas partners, mirroring the approach behind its expanding Megapack production in Brookshire, Texas, where Tesla has already built out two buildings for its grid battery business.

The timing lines up closely with Tesla and SpaceX’s other big Texas commitment this month. SpaceX confirmed its Terafab chip factory would land in Grimes County days before this filing surfaced, with construction on that $16.8 billion project starting almost immediately after local officials met with residents. Terafab is meant to produce the AI chips running Tesla’s Optimus robots and Full Self-Driving software, while a solar cell plant would feed a different part of the business, the panels and storage systems Tesla sells to homeowners, businesses and utilities, and increasingly needs to power its own data centers.

Musk has talked about building domestic solar manufacturing capacity before, tying it to the amount of power Tesla’s AI ambitions will require.

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