Energy
Tesla Solar Roof takes step towards new variants with textured, colored tile patent
It appears that Tesla is working on some improvements for its Solar Roof tiles that may allow the company to release new variants of the flagship solar product. These potential Solar Roof improvements were discussed extensively in a recently-published patent, which described how the electric car and energy company intends to roll out tiles that feature a better, more seamless appearance.
Tesla’s Solarglass Roof tiles are already among the most aesthetically-pleasing PV systems in the market. A Solar Roof installation involves the setup of both PV and non-PV roof tiles, and according to Tesla, this could present some issues. Since some tiles do not have solar cells in them, there will be some angles or times when it is possible to distinguish which tiles have solar cells and which do not.
Tesla described this issue in the background of its patent, titled “System and Method for Improving Color Appearance of Solar Roofs” and published on February 11, 2021.
“When viewed from a shallow angle (e.g., when the roof is viewed from the street), the dark-colored photovoltaic structures can become visible. The color contrast between the photovoltaic structures and the glass cover can create a scene that is not aesthetically pleasing… Although the non-PV roof tiles can include similar glass covers as those of the PV roof tiles, the absence of embedded photovoltaic structures can result in the non-PV roof tiles having a different color appearance than that of the PV roof tiles.”
Tesla notes that these issues are due to several factors, including tiny imperfections during the Solar Roofs’ manufacturing process or the fact that PV roof tiles tend to look different when viewed under different lighting and at different viewing angles. According to Tesla, there are ways to get around these challenges, such as adopting a robust color-management scheme and some adjustments in the Solar Roof tiles’ manufacturing line.
“First, to reduce the color contrast within a PV roof tile, the PV roof tile can encapsulate polycrystalline-Si-based photovoltaic structures. By controlling the size and pattern of the surface texture of the polycrystalline-Si-based photovoltaic structures, one can reduce the “glow” of the photovoltaic structures. While keeping the front cover of the roof tile transparent, the back surface of the back cover can be coated with a layer of paint that matches the color of the textured surface of the photovoltaic structures to reduce the color contrast within the PV roof tile. A similar paint layer can also be deposited onto the back surface of the non-PV roof tiles.”
“As a result, the color appearance of the PV and non-PV roof tiles can be quite similar. Moreover, when assembling the PV roof tiles, the embedded photovoltaic structures are fed into the production line following a predetermined color pattern such that a majority of PV roof tiles contains solar cells of a similar color and PV roof tiles of different colors are evenly or randomly mixed to prevent clustering of colors on a roof.”
Through these methods, Tesla noted that it would be able to create Solar Roof tiles that feature much less “glow” than typical integrated PV systems. The patent also covered how reactive ion etching (RIE) techniques could be utilized to create textured PV roof tiles. These invoke images of the various Solar Roof variants that Elon Musk unveiled in 2016, which included textured tiles that mirrored the appearance of materials like slate and clay.
“The surface of a polycrystalline-Si-based solar cell can be textured using a reactive ion etching (RIE) technique. In further embodiments, the feature size of the RIE-textured surface can be less than 1 micron (i.e., 0.5 micron or less). In alternative embodiments, the surface of the solar cells can have pyramid texturing with the base width of the pyramids being less than 1 micron (e.g., 0.7 micron or less). Compared to the textured surface of a monocrystalline-Si-based solar cell, the RIE-textured surface of the polycrystalline-Si solar cells can have improved surface uniformity. As a result, the PV roof tiles can have reduced color flop and glow.”
“In alternative embodiments, reducing the cell glow can be achieved through specifically designed anti-reflection coating. This specially designed anti-reflective coating (AR) on a monocrystalline-Si-based solar cell surface can include materials with a higher refractive index than a conventional AR coating (e.g., an indium tin oxide (ITO) coating). More precisely, the specifically designed AR coating can include a layer of SiNx or a SiOxNy /SiNy double layer structure. As a result, the cell glow can be reduced by three- to eightfold with low (e.g., less than 5%) power loss.”
Elon Musk has stated that 2021 will be a key year for the Solar Roof, with the CEO noting that its potential would be evident this year. Considering the company’s ongoing rollout of the integrated PV system and the development of better Solar Roof designs, it may only be a matter of time before more customers of Tesla’s flagship residential solar product would have more design options available.
Read Tesla’s recently-published Solar Roof patent could be accessed here.
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Tesla has chosen the location of its latest manufacturing project, a facility that will churn out the Megapack, a large-scale energy storage system for solar energy projects. It has chosen Waller County, Texas, as the location of the new plant, according to a Commissioners Court meeting that occurred on Wednesday, March 5.
Around midday, members of the Waller County Commissioners Court approved a tax abatement agreement that will bring Tesla to its area, along with an estimated 1,500 jobs. The plant will be located at the Empire West Industrial Park in the Brookshire part of town.
Brookshire also plans to consider a tax abatement for Tesla at its meeting next Thursday.
The project will see a one million square-foot building make way for Tesla to build Megapack battery storage units, according to Covering Katy News, which first reported on the company’s intention to build a plant for its energy product.
CEO Elon Musk confirmed on the company’s Q4 2024 Earnings Call in late January that it had officially started building its third Megapack plant, but did not disclose any location:
“So, we have our second factory, which is in Shanghai, that’s starting operation, and we’re building a third factory. So, we’re trying to ramp output of the stationary battery storage as quickly as possible.”
Tesla plans third Megafactory after breaking energy records in 2024
The Megapack has been a high-demand item as more energy storage projects have started developing. Across the globe, regions are looking for ways to avert the loss of power in the event of a natural disaster or simple power outage.
This is where Megapack comes in, as it stores energy and keeps the lights on when the main grid is unable to provide electricity.
Vince Yokom of the Waller County Economic Development Partnership, commented on Tesla’s planned Megapack facility:
“I want to thank Tesla for investing in Waller County and Brookshire. This will be a state-of-the-art manufacturing facility for their Megapack product. It is a powerful battery unit that provides energy storage and support to help stabilize the grid and prevent outages.”
Tesla has had a lease on the building where it will manufacture the Megapacks since October 2021. However, it was occupied by a third-party logistics company that handled the company’s car parts.
Tesla Energy has become the undisputed dark horse of the electric vehicle maker. This was highlighted by Tesla Energy’s growing role in the company’s overall operations in the past quarters.
And as per Tesla’s year-end milestone posts on X, Tesla Energy had a blockbuster 2024.
Tesla Energy’s 2024 milestones:
- As per Tesla on its official social media account on X, the company has hit over 800,000 Powerwalls installed worldwide.
- From this number, over 100,000 Powerwall batteries have been enrolled in virtual power plant (VPP) programs.
- The Powerwall 3 has officially been launched in the United States, Canada, Puerto Rico, the U.K., Germany, Italy, Australia, and New Zealand.
- The Tesla Megapack hit over 22 GWh in operation across more than 60 countries across the globe.
- The Lathrop Megafactory, which produces the Megapack, has been ramped to 40 GWh per year.
- The Lathrop Megafactory has also produced its 10,000th Megapack battery.
- The Shanghai Megafactory was completed in just seven months, and it is ready to start Megapack production in Q1 2025.
Hit 800k Powerwalls installed worldwide
— Tesla (@Tesla) December 31, 2024
Also:
– Over 100k Powerwalls are now enrolled in VPP programs
– Launched Powerwall 3 in the US, Canada, Puerto Rico, UK, Germany, Italy, Australia & New Zealand
– Megapack hit 22+ GWh in operation across 60+ countries
– Ramped… pic.twitter.com/bE88DpeyTg
Powerwall owners’ 2024 impact:
- As per Tesla Energy, Powerwall owners generated a total of 4.5 TWh of solar energy globally in 2024. This was equivalent to powering a Model 3 for more than 17 billion miles.
- A total of 1.1 TWh of energy was stored in Powerwalls in 2024. This protected homes from over 5.8 million outages during the year.
- Tesla’s Storm Watch feature for Powerwall batteries covered 2.8 million severe weather events over the year.
- Powerwall owners saw collective savings of over $800 million on utility bills.
- Virtual Power Plants contributed over 2.2 GWh of power to the grid. This reduced the need for 2,200 metric tons of fossil fuel peaker plant emissions.
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Utah-based rPlus Energies recently held the groundbreaking ceremony for the Green River Energy Center, a 400 MW solar PV and 400 MW/1,600 MWh battery storage project in Eastern Utah. Tesla Megapacks will be used as the upcoming facility’s battery storage solution.
At 400 MW/1,600 MWh, the Green River Energy Center is expected to become one of the largest solar-plus-storage projects under development in the United States. Once operational, the facility would supply power to PacifiCorp under a power purchase agreement, as noted in a press release.
Utah Gov. Spencer Cox shared his excitement for the project during the Green River Energy Center’s groundbreaking event. As per the Utah Governor, the solar and battery storage system represents a notable step forward for the state’s sustainable energy efforts.
NEWS: rPlus Energy has just broken ground on a new $362 million @Tesla Megapack battery energy storage system in Utah.
This 400 MW solar PV and 400 MW/1,600 MWh battery storage project is one of the largest solar-plus-storage projects under construction in the nation. The entire… pic.twitter.com/ubPOUnPWEf— Sawyer Merritt (@SawyerMerritt) September 24, 2024
“This project is being built in rural Utah, by rural Utahns, and for all of Utah. When rural Utah thrives, the entire state prospers. Today, we’re not just breaking ground—we’re building a future of affordable, abundant energy in Utah,” the official noted.
The Green River Energy Center secured over $1 billion in construction debt financing earlier this year. The facility is also expected to create about 500 jobs, many of which will be filled by local workers. With this in mind, the solar and battery farm would likely prove to be a boost to Emery County’s economy, enhancing tax revenue, strengthening public services, and offering long-term employment opportunities for the area’s residents.
Sundt Construction will serve as the project’s contractor, EliTe Solar will supply the solar modules, and Tesla will provide the battery storage system for the project. Luigi Resta, President and CEO of rPlus Energies, noted that the Green River Energy Center is special because of the entities that have worked together to make the facility a reality.
“It’s the partners that make this project special, that have made this monumental project possible. From our equipment providers to the onsite talent, and the support of the local and regional community, we owe this project’s success to each of you,” he stated.
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