Swatches | April 1, 2025 | By: ATA

Solar-structure manufacturer Pvilion, of Brooklyn, N.Y., is partnering with fabric ag building manufacturer Accu-Steel Inc., headquartered in Templeton, Iowa, to test an “agrivoltaic” structure for farmers. With the addition of walls, it could serve as an off-grid shop or livestock shelter or have other uses.

The 12,000-square-foot structure integrates 42 kW of solar power and a lithium-ion battery bank that can store 135 kWh, allowing the building to supply its own power for typical needs such as lighting and computers as well as the energy needed to run equipment including tools for cutting and welding, irrigation pumps and fans, or space heaters for keeping livestock comfortable. But that’s just the start.

“The solar fabric roof and electrical system is electrically connected to the main electrical panel for the entire farm, including the owner’s home, offices and manufacturing facility,” says Robert Lerner, co-founder and vice president of Pvilion. “Anything that uses power at the farm, house and factory can draw power from the solar roof and battery bank. If the electrical grid goes down, this solar roof is sized to be able to power the entire facility.”

The system can pull power from the grid to charge the batteries when they fall below a certain threshold, but the power grid is essentially backup power for the farm.

Uses of the structure and the battery bank and solar array as well as the system’s electrical and structural performance are under evaluation by the companies as they develop the business case for the product. With this installation, Pvilion is also testing two different ways to adhere the solar panels to the fabric. The building and installation would qualify for a federal solar tax credit.

To view the original article, click here.

North American Clean Energy Magazine | March/April 2025 | Julia Fowler

In any state of emergency, two of the most essential resources are shelter and power. Failing to immediately address the unequivocal need for shelter and power during times of crisis leaves communities vulnerable and limits emergency responders’ ability to provide crucial support. 

The aftermath of unexpected disaster

Disaster can strike unexpectedly anywhere at any time. States of emergency can be declared due to natural disasters such as earthquakes, wildfires, hurricanes, extreme temperatures, tornadoes, wildfires, and floods. Public health crises, civil emergencies, and military conflict are also leading causes of states of emergency.

According to the National Centers for Environmental Information, there were 27 weather and climate disaster events within the United States that were large enough to cause losses exceeding $1 billion each in 2024. These events included flooding, droughts, hurricanes, tropical cyclones, wildfires, and winter storms.

When disaster strikes and a state of emergency is declared, the appropriate emergency management teams will take action in the affected communities. In the US, emergency response operations are typically organized by the Federal Emergency Management Agency (FEMA).

Acting fast to address the most essential needs 

In times of disaster, shelters act as the base for many essential functions. It is one of the most basic requirements for survival — often taught in entry level psychology classes, under the popularly known Maslow’s Hierarchy of needs, shelter falls under the most elemental human need, physiological needs. In fact, shelter is so critical that it is recognized as one of the “core clusters” by the United Nations for greater coordination in humanitarian crises. The cluster approach is activated by the Emergency Relief Coordinator as an approach for non-refugee humanitarian emergencies to efficiently meet the most critical needs of affected populations.

Not only does shelter act as a place of refuge and safety, but it creates space for privacy, dignity, sense of security, treatment, and recovery. Temporary shelters provide rapid solutions during the response phase of emergencies allowing for smoother transitions toward recovery following disaster.

It is imperative that emergency shelter solutions are easily accessible and rapidly deployable in any setting. Temporary shelter may be used to set-up resiliency hubs, medical facilities, temporary housing, distribution centers, supply storage, communication and command centers, and many other first-response hubs. 

The unequivocal need for power

Power is a vital resource in times of crisis; without access to a power source, there is no access to medical equipment, heating and cooling systems, communication tools, lighting, water supply, and other critical devices. In remote locations and areas left with disruptions to the local power grid, the need for a reliable power source can be life or death.

The power of solar in times of crisis

Historically, traditional diesel generators have been viewed as the standard power source in times of emergency. Today, more users are considering solar to be the ideal solution for backup power sources as more battery systems and clean energy sources become accessible through wide-ranging system sizing, user friendly interfaces, improved safety features, and financial incentives. 

Aside from being environmentally conscious, there are many advantages when opting for solar in place of traditional generators. For example, one of the greatest benefits of choosing solar is the drastic reduction in the need for fuel. Since solar power is continuously derived from photovoltaic panels, the need for fuel can be completely eliminated in many settings, and when solar cannot be the sole source of power, the generator system size required is drastically reduced, as is the need for fuel resupply. Additionally, the battery systems used in solar power systems are completely silent – unlike the loud and ear damaging roar of a diesel generator – improving conditions in emergency settings by minimizing noise pollution. 

New technology on the market

Today, companies specializing in unique innovative technology like this have successfully created solar powered fabric that is integrated with lightweight photovoltaic cells, making solar power more readily accessible, significantly lighter, and more resilient. Without glass panels, solar can be accessed in more settings, easily erected, and used without the fear of glass panels cracking or breaking.  

With Using this advanced solar technology, companies like Brooklyn-based Pvilion are designing turnkey solutions that provide rapidly deployable shelter that is connected to mobile battery kits. that These provide enough power for equipment, heating and cooling systems, communication tools, lighting, water supply, and other critical devices. Thanks to the flexible nature of the solar fabric and modularity of the mobile battery systems, Solar Powered Integrated Structure (SPIS) kits are easily packed up for travel and storage and can be assembled with minimal manpower within minutes.

Additionally, since the solar and batteries are integrated with the shelter system, the entire Solar Powered Integrated Structure (SPIS) kits qualify for a 30 percent tax credit under the Inflation Reduction Act. Under this act, nonprofits, government agencies, and other tax-exempt entities may still benefit through the Elective Pay Provision.

Author is Julia Fowler at Pvilion, which integrates solar cells with fabric, and builds fabric products that generate electricity. Pvilion | www.pvilion.com

See below for the original publication’s press clippings:

February 25, 2025 | Tina Casey

Though conservative backlash against the ESG movement continues in the United States, anti-ESG legislation does not necessarily reflect public opinion. The principles of sustainment, a set of guidelines used by the U.S. military, offer inspiration for businesses looking for alternative language to describe their sustainability efforts in this environment.

The solar startup Pvilion builds flexible, transportable, solar-enabled structures for customers including the United States military.

As the political temperature of the corporate ESG (environment, social and governance) movement continues to rise, some business leaders are searching for alternative language to describe their sustainability efforts. They may not have to look far. The principles of sustainment are key guidelines for United States military logistics, and they sound very much like the sustainability goals articulated by the corporate ESG movement.

Sustainability is sustainment

In parallel with corporate sustainability efforts, the U.S. Army lists foresight, efficiency, flexibility and a willingness to adopt new technologies as essential to the principles of sustainment, emphasizing that they must be integrated throughout an operation, similar to the integrated model that underpins the ESG movement.

TriplePundit learned more about the parallels between sustainability and sustainment during a visit to the Brooklyn solar startup Pvilion. In addition to producing architectural solar systems, Pvilion manufactures flexible, transportable, solar-enabled canopies for the U.S. military and other customers.

Colin Touhey, Pvilion CEO, drew attention to tax credits, aesthetic appeal and other benefits of solar-embedded architectural structures. The company integrates solar cells into fabrics to create products like canopies, tents and building facades that generate electricity. Transportable solar energy systems can also reduce dependency on diesel generators, an important logistical consideration for military operations in remote locations where fuel transportation is difficult, expensive and potentially dangerous, he said.

Workforce benefits are additional factors. Based on conversations with hands-on personnel who repair and maintain diesel generators, Touhey found that solar energy systems are easier to work with and support a more healthful, less noisy environment. They also avoid logistical complications related to diesel generator breakdowns, parts replacement and fuel supply. 

“People who work with [diesel] generators are our biggest advocates,” Touhey said. “Sustainment focuses on the customer’s functions.”

The next steps for Pvilion include developing a self-forming solar canopy, which the Air Force is currently demonstrating. Equipped with a solar-powered robotic system, the canopy can assemble itself in just 60 seconds. A standard canopy requires several people and about 30 minutes to set up manually.

In addition to the benefits of solar energy, the self-forming canopy demonstrates how sustainable technology can have a ripple effect on other elements of an operation. “If you need fewer people, you need less water, fuel and food,” Touhey said.

Sustaining national security with renewable energy

On a larger scale, the Department of Defense began installing utility-sized solar arrays and rooftop solar panels at its bases during former President Barack Obama’s administration to improve energy security and resiliency at its facilities. The new federal energy policy announced in an executive order by President Donald Trump last month may place some obstacles in the way moving forward, but military analysts continue to make the national security case for renewable energy. Their perspective mirrors the sustainability concerns of businesses.

Researchers from the international security think tank Stimson Center, for example, describe the benefits of on-site renewable energy in an opinion piece for Defense News. They note that many U.S. bases are vulnerable to energy supply disruption due to their reliance on the civilian grid for electricity and diesel fuel transportation networks for backup power.

“It is too expensive for the Department of Defense to fortify the entire electric grid; it is far easier to ensure energy resilience on bases instead,” they wrote.

Next steps for the language of sustainability

Some businesses changed the words they use to discuss sustainability with clients and customers when conservative backlash against the ESG movement accelerated during former President Joe Biden’s administration. Still, anti-ESG legislation does not necessarily reflect public opinion. In 2023, for example, the communications firm Rokk Solutions found that a strong bipartisan majority of voters recognize they personally benefit from corporate conservation efforts and other specific actions.

A survey conducted last fall by the research firm YouGov on behalf of Whole Foods also underscored the popularity of corporate sustainability efforts among younger consumers, finding that almost 75 percent of Generation Z consumers are concerned about the climate, 70 percent support climate-smart agriculture, and more than 50 percent choose brands that emphasize local sourcing and environmental protection. 

“The study reinforces a growing demand among younger generations for clear information about sustainability to make informed purchasing decisions,” according to YouGov.

The strategic planning firm Trajectory Partnership also emphasizes the need for clarity and specificity. Everyday language is a more effective way for businesses to communicate sustainability, according to a survey the firm conducted last year. “Many terms such as ’carbon neutral’ and ’net zero’ are either poorly understood by consumers or polarize opinion,” according to Trajectory. “Other terms such as ’locally sourced’ or ’recycled’ are much better understood.”

A new survey from the software company Workiva also indicates the corporate sustainability movement is a permanent trend, regardless of politics.  Among other findings, 97 percent of executives surveyed said sustainability reporting will be a business advantage within two years, and 85 percent are continuing their climate disclosure plans despite the shifting political environment.

Finding the right words to reach consumers and clients in the U.S. while competing in the global marketplace is more important now than ever. The months and years ahead will challenge the ability of U.S. business leaders to communicate openly and effectively about their ESG programs. Still, in Europe and elsewhere the decarbonization movement is accelerating, and consumers will not stop demanding transparency. 

To view the original article, click here.

From powering the Red Cross to Coldplay concerts

March 3, 2025 | Andrew Scott

Coldplay’s performance powered by Pvilion. Photo courtesy of Pvilion

INDUSTRY CITY — Colin Touhey, co-founder of Pvilion and lifelong Park Sloper, believes solar can be our main energy source, not just because of how fast it’s growing but also because of how much cheaper it is than fossil fuels. Solar costs have dropped 90% in the last decade. And, if part of an efficient system of batteries and other renewables, as California has proven, solar can replace fossil fuels entirely.

But, one of the restrictions of solar panels is their confinement to, well, panels. To push the boundaries of solar, Pvilion pioneers products with solar cells integrated into fabric — right here in Brooklyn.

The Eagle met with Touhey and the team in Sunset Park overlooking Gowanus Bay. “Industry City was able to find us a happy medium between a nice quality office and manufacturing space — a warehouse, freight trucks — it’s a hard thing to find in Brooklyn,” he said, stressing his appreciation for Blocpower, the Brooklyn Chamber of Commerce and the job training benefits of being in Brooklyn. “It’s not just talk; it’s really happening.”

Pvilion offers adaptable, lightweight solar power for everything from disaster relief shelters to concert tours, reducing reliance on fossil fuels.

Half of its products are temporary military relocatable structures and half focus on landscape architecture.

The urgent necessity of alternative power

The 2016 Paris Agreement, which President “Drill, baby, drill” Trump recently pulled out of, claimed to “pursue efforts to limit the temperature increase to 1.5 degrees C above preindustrial levels” when permafrost thaws, releasing more greenhouse gases.

In 2018, experts predicted we might cross 1.5 degrees C between 2030-2052. A 2023 assessment moved the timeline up to 2021-2040. But just last year, we reached a new 1.6 degrees C record.

New research using AI shows a very high likelihood of 2.0 degrees of warming for most of the globe by 2040 and 3.0 degrees C by mid-century. Even if we aggressively reduce emissions, 76.5% of Earth will see 3.0 degrees C by 2100.

At this point, we’ll have to start the process of decarbonization.

It’s evidently becoming difficult to keep track of the factors contributing to climate change. Global forests emitted more than they absorbed in 2023. Last year, 41% of the Arctic, normally a carbon sink, became a carbon source, mostly from Alaskan permafrost thaw.

Globally, emissions increased by 2% due to the absence of legislation. Under Biden, the U.S. dropped emissions by a whopping 0.2% last year, but they likely will increase under Trump, who recently ordered the removal of the climate change page from the EPA’s website.

With ever-increasing energy demands from technologies like cryptocurrency mining and AI, we need more alternative energy options. That’s where Pvilion comes in with a highly adaptable solution.

What exactly can solar fabric do?

There’s a lot you can do with solar cells integrated into fabric. Traditional solar panels are large slabs of glass and metal weighing around 80 pounds. “This is five times bigger and weighs 50 pounds. Two people can pop this up,” Touhey told the Eagle, holding a folded accordion solar array.  

Because it’s flexible, the chemistry is a little different, but Touhey says Pvillion’s solar fabric functions just as well as its more cumbersome counterpart. Fashioning a solar fabric hat could technically charge your phone. “The surface area to charge a cell phone is about an 8 ½” by 11” piece of paper.”

The company specializes in 10 forms of tents, including thinner options that fold and more rigid ones. The most popular mass-produced application robotically self-assembles, providing shelter and power. 

I followed Touhey into a military-grade tent with a floor, walls, windows, doors, lights, plugs and an HVAC unit — all built into a system that unfolds at the push of a button from a pneumatic tire cart housing the battery. Together, the entire self-sustaining package weighs hundreds of pounds, but a motor in the cart makes it easy to trolley off-road. The package contains a lithium iron phosphate battery (LFP) system that automatically regulates when to expend energy or charge.

LFPs, the second most popular type of lithium-ion battery after lithium nickel manganese cobalt (NMC) batteries, hold less energy than NMCs but expend it faster and charge faster. They’re generally better for the environment due to the absence of cobalt, and they’re safer, allowing for airdrop, which is essential for Pvilion.

The tents are pivotal for disaster relief and humanitarian aid. Pvillion works with Air Force contingency response teams — the first to arrive at a disaster and prepare semi-permanent infrastructure for the Red Cross. “If you go to the middle of the desert and you need 10 tents, the amount of fuel you have to bring in is insane,” Touhey clarified, “you’re running generators the entire time on diesel fuel, so the idea that you can go to zero is pretty meaningful for them.”

Pvilion has provided refugee tents for displaced Ukrainians in Poland, but they also collaborated with Tommy Hilfiger on two limited edition solar-powered jackets that can charge a tablet.

For the last two years, Pvilion has been working on a rental and service program specifically for the five boroughs, but renting is also part of their regular product line.

One of their recent clients was Coldplay. With a fabric solar array in the empty seats behind the stage, Pvilion supplied a significant portion of the band’s electricity, which would have otherwise been all diesel fuel. “Cause they don’t get power from the stadium,” Touhey told the Eagle, “They have to power 100% of their stuff even though they’re in a permanent stadium.”

Because it was a pilot program, diesel supplemented the array, but Pvilion is confident that a larger battery system would allow performers touring stadiums to cut gas completely. “It’s just a matter of cost and scale.”

Pvillion also has semi-permanent canopies at the New York Botanical Garden that can be moved around. The canopies can charge anything from food trucks to farmers’ market point-of-sale machines to cell phones. They crafted a solar carport, about the size of four parking spots, that can power four car chargers, as well as a cafe trellis for Google. For Home Depot, Pvillion developed solar awnings that can charge heavy equipment.

The first solar fabric

Pvillion co-founder Robert Lerner got involved with using fabrics as a substrate for solar cells in the mid-90s.

Lerner was working at FTL Design Engineering when Cooper Hewit hired the firm to do an experimental design for an exhibit on the history of solar energy. Kiss & Cathcart, another design firm hired to collaborate with FTL on the exhibit, created a pavilion with semitransparent amorphous silicon solar panels laminated into glass.

Lerner and his team asked Kiss & Cathcart if they could use the same solar cells to create a portable tent, and with some funding from the New York State Research and Development Authority (NYSERDA), it became the world’s first solar fabric.

The U.S. Army eventually contacted them after seeing it in a magazine and awarded the group a Small Business Innovation Research (SBIR) contract with Kiss & Cathcart, who got most of the money to develop the solar cells, which were uncommon at the time.

Their first product was called The Power of Shade: a tent that went over other tents, reducing the heat load on the inner tent while generating electronic power.

“The research and development process [with the military] is so slow that we moved to the private sector,” Touhey added. After going from SBIR funding to NYSERDA funding, they got some private investors and moved into the commercial market. The team split into FTL Solar — when Touhey joined — before finally forming Pvilion.

Around 2019, Pvillion went back to the military through a program in the Air Force for small businesses with commercial products called AFWERX, securing $75,000 to meet with people for 3 months. “They pay you to travel around and ask people, ‘What would you use this for?’” One person might want it for air traffic control towers and another for air conditioning in a tent.

After submitting a report, Touhey said, “We’re going to build these prototypes to prove this technology we developed for the New York Botanical Gardens works for air traffic control towers.”

Looking forward

In the near future, Pvilion will supply New York State with portable solar charging stations for electric construction and agriculture equipment. It’s technically two programs, one replacing generators on construction sites here in Brooklyn and the other doing the same for farming upstate.

Electric industrial and construction are essential, but clean charging infrastructure is necessary. “Otherwise, you’re just using a diesel generator to charge an electric bulldozer. That’s not really solving your problem.” Touhey hopes to partner with some bigger companies on this.

There are countless potential applications of solar fabric. Floating solar came up. Even for large buildings that can’t handle the weight of solar panels, Pvilion offers something that weighs 10 times less. “There are a lot of buildings where the roofs and the actual structures themselves are fabric,” Touhey said, mentioning cattle barns, salt sheds, and an Accu-Steel-style tent just outside.

He gestured out the window to a chainlink construction fence with a privacy screen, “All of that fence is fabric, right? Solarize that, you’re good — you know?”

“There’s free energy all over the world,” Touhey went on, “The idea that any piece of fabric that’s getting hit by the sun is an opportunity to generate electricity was pretty intriguing to me … It’s a big opportunity that is untapped.”

To view the original article, click here.

Architecture New York State Magazine | December 2024 | Robert Lerner

AIA New York State recently shared an article about photovoltaic tensile structures by Pvilion co-founder, Robert Lerner, in the December issue of Architecture New York State Magazine.

To view the full December issue of Architecture New York State Magazine, click here.

December 2024

In recent weeks, Pvilion team members visited USAFE at Spangdahlem AFB in Germany to install Pvilion SPIS on aircraft hangars. 

The solar power generated will be used to power the entire hangar, including the structure’s hydraulic doors. The SPIS fabric can be easily removed, packed up, and used for mobile applications when needed. 

This application of Pvilion’s Solar Powered Fabric provides a uniquely flexible solution for large industrial buildings in a variety of settings. 

Hangars, warehouses, agricultural facilities, and all other large industrial structures can use Pvilion Solar Powered Fabric to retroactively use lightweight solar power, regardless of the building’s shape. 

Pvilion’s patented solar technology is integrated with thin, flexible, lightweight solar panels. It is designed to be waterproof, fire-retardant, UV-resistant, and durable enough to withstand extreme wind loads and weather conditions. It can be added to existing temporary or permanent structures like this aircraft hangar. 

To watch the video about this project, click here.

By: Paolo von Schirach

How about a tent that produces the electricity necessary to satisfy the needs of campers or field hospitals? Pvilion, a U.S. company based in Brooklyn, New York, can make them for you, following your specifications in terms of size and preferred material. Is this the new frontier of solar energy applications?

When we think about renewable energy, we generally think wind and solar. These days, solar panels are very popular. We can have a large number of them, arranged in rows, and this becomes a large solar power plant connected to the electric grid that can supply enough electricity to satisfy the power needs of thousands of homes. Or we can have some panels on the rooftops of individual structures, commercial buildings, or homes, that will satisfy the electricity needs of those buildings.

Because of significant cost reductions in the manufacturing of solar panels, in the last few years, prices for solar have plummeted worldwide. Hence, a huge demand increase. Along with the rest of the world, in the U.S., there has been an explosion of demand for solar panels, especially in California, the U.S. state traditionally in the lead when it comes to adopting innovative, renewable energy solutions.

But now we see that in the U.S., demand has peaked. While the market is still good, there is far less enthusiasm for solar. In part, this has to do with cost. While costs have come down, now the big savings in the U.S. are gone.

And here are some reasons. Most solar panels are imported from China, by far the largest world producer (about 80 percent of total supplies). U.S. providers now want to rely more on U.S.-made panels. However, these panels cost more because the U.S. industrial base for solar is much smaller. Therefore, no economies of scale. And then customers now have to deal with higher installation costs. Besides, the generous schemes whereby utilities in the past paid good prices for excess electricity supplied to them by individual households equipped with solar panels have been phased out. Therefore, while overall the cost of panels is down, the huge economic advantages that existed until recently now have largely disappeared.

Another drawback with these conventional solar panels is that they are rigid structures, therefore not easily adjustable to the specific needs of individual customers, while other needs could not be met at all.

Enter Pvilion. This company has come up with innovations that make solar more appealing for buyers who need customized products. Working with specialists who have optimized the design of various types of tents and coverings, large and small, Pvilion developed a technology to embed solar panels into various fabrics.

This way, one can have tents and coverings with solar energy generation embedded in them that can be easily folded and transported, just like regular tents. With this innovation, new markets for solar power can be opened and developed. Think of tents and other movable structures used by the military in remote areas, field hospitals in battle zones, or first responders supplying people stranded by hurricanes or floods.

Now all of these entities can pack tents with embedded solar panels that can be folded, unfolded, and set up on-site, without the need to transport clunky solar panels to provide power to the camps. Likewise, no need to transport heavy generators and all the fuel necessary to power them. With solar-powered tents, first responders or expeditionary military forces can have the power supply they need without adding the weight and inconvenience of loading up extra equipment.

The same value proposition applies to the organizers of major events, such as big concerts. Instead of carrying heavy generators for lights and electronic instruments and all the fuel necessary to power them, the whole power supply will be in the canvas of the movable tents or coverings that will have to be carried anyway to provide enclosed spaces for the events.

Thanks to Pvilion’s customized products, these end-users can have at the same time tents, canopies, shelter structures, and power generation. By recognizing these new markets, Pvilion has broadened the potential customer base for solar energy solutions.

Original Source: https://globalpi.org/research/solar-electrical-power-from-fabrics/.

2024 Annual International Achievement Awards

For more than 75 years, the International Achievement Awards (IAA) recognize outstanding and innovative projects representing the latest accomplishments in design and manufacture incorporating specialty fabrics. The 46-category competition, sponsored by ATA (formerly known as IFAI) since 1946, is an excellent opportunity for ATA members and non-members to display work, gain professional recognition and become distinguished on an international level.

The IAA’s have recognized technical skill and design excellence in projects across the industry that incorporate specialty fabrics into their design. Entries are judged by industry experts and design professionals who are individually selected for their expertise in a particular field of study or product area. All projects entered are automatically listed in the IAA online gallery which is promoted year-round. Grow your brand, showcase your talent, and get the recognition you deserve! To view the IAA website, click here.

To view the original award listing, click here.

Features | October 1, 2024 | By: Debra Cobb

According to the International Energy Agency (IEA), the amount of renewable capacity added to energy systems around the world grew by 50% in 2023, reaching almost 510 gigawatts (GW), with solar/photovoltaic accounting for three-quarters of additions worldwide.

The IEA forecasts that U.S. solar power generation will grow 75% from 163 billion kilowatt hours (kWh) in 2023 to 286 billion kWh in 2025. The agency also expects wind power generation to grow 11% from 430 billion kWh in 2023 to 476 billion kWh in 2025. Hydrogen power and sustainable aviation fuel (SAF) are also poised for growth.

The economic opportunities the generation of alternative energy provides—requiring new facilities, new materials and a wide range of feedstocks—could likewise fuel the growth of innovative technical textiles. Seen and unseen, these critical components include unique polymers, composites, membranes and filters as well as performance textiles for wind and solar that are lighter, stronger and often recyclable.

From solar cells to solar fabric

Recent developments in lightweight, super-thin, flexible photovoltaics have enabled the solarization of fabrics, expanding the potential range of energy-producing form factors. Brooklyn, N.Y.-based company Pvilion laminates its solar cells to various textiles to create a range of canopies, tents, curtains, building facades, backpacks and clothing. “Once you have the panel, you can turn it into anything,” says Colin Touhey, company co-founder and CEO.

Pvilion’s advantage is in its systems that provide both shelter and power in one structure to partners such as Carnegie Hall, Bloomberg, Tishman Speyer, New York City, Yale University, the U.S. Air Force, the Florida Department of Transportation and the city of Miami.

“Solar fabrics are getting better and better,” Touhey says. He explains that the company is agnostic regarding substrates, focusing instead on durability and longevity. Pvilion creates solar fabrics from ripstop nylon, PVC-coated polyester, polytetrafluoroethylene-coated fiberglass, Dyneema®, and sometimes stretch substrates.

“We are more and more trying to build a line of finished products, as mass production is the goal for price,” says Touhey. “But we are happy to work with people who have a small volume. Being a solar power company doesn’t mean anything if it doesn’t fit into the customer’s requirements.”

From sails to wind turbines

Scottish startup ACT Blade is working with an innovative fabric and specialized modular manufacturing system for turbine blades. The new blades are longer without increased weight and comprise fewer materials and simpler, streamlined production methods. They feature a slender supporting structure made from a composite material that the technical textile completely covers.

Concordia Textiles Group, based in Waregem, Belgium, manufactures the protective outer shell for the wind turbine blades. The fabric is reparable and is composed of elements that can be easily separated for recycling at end of life.

“We developed a laminate that is the common denominator of more than 20 technical requirements by combining the strength and elasticity of a fabric with a protective layer,” says Rik Gekiere, Concordia’s sales and product manager. “Rain-erosion resistance and durability over time were the most challenging to achieve.”

Enel Green Power, an Italian multinational renewable-energy corporation, is partnering with ACT Blade to develop the project. A wind technology called OceanWings®, patented by VPLP Design in France, is said to enable a 45% savings in fuel consumption and a subsequent reduction in carbon dioxide equivalent (CO₂e) emissions for sailing vessels. The vertical windsails provide aerodynamic lift and feature automated positioning to maximize thrust.

OceanWings are made from eco-composites that include linen fiber and recycled thermoplastic resins. The outer bag is 1,000-denier nylon with a layer of urethane to protect against punctures and abrasion.

The sails were first trialed in 2019 on the Energy Observer, an experimental vessel designed to test alternative energy sources in maritime conditions. In 2022, a commercial wind-powered cargo ship, the Canopeé, launched with four OceanWings that reduce
fuel consumption by up to 42% in good weather conditions.

Green hydrogen: Fuel of the future?

The World Economic Forum defines green hydrogen as hydrogen produced through electrolysis, using renewable electricity from solar or wind to split water into two hydrogen atoms and one oxygen atom. Green hydrogen can be used to decarbonize transportation, including heavy trucks, aviation and shipping, as well as in the manufacturing of steel, cement and other hard-to-abate industries.

At the heart of the green hydrogen process are proton exchange membranes, or PEMs. These membranes play a vital role in hydrogen production, fuel cells and flow batteries for energy storage. The company Chemours™, based in Wilmington, Del., dominates this market with its Nafion™ brand portfolio of membranes, dispersions and resins.

Nafion is a synthetic polymer with unique ionic properties, created by incorporating perfluorovinyl ether groups terminated with sulfonate groups onto a PTFE backbone. The resulting product is a thermoplastic that can be extruded or solution-cast into films for composite membranes.

In response to a request for information, Nafion portfolio’s product manager referred to a paper published by Chemours’ technical team: “Advancements in Thin, Reinforced Proton Exchange Membranes for Water Electrolysis” by Ryan Gebhardt and others.

“Employing a thinner and mechanically supported membrane can enhance both the electrochemical performance and mechanical properties. With the demand for cheaper hydrogen, these new membrane designs are needed to achieve advanced performance metrics,” the paper states.

While the green hydrogen economy is still in its infancy, the U.S. Department of Energy (DOE) recently announced $750 million, funded by the 2022 Bipartisan Infrastructure Law, for 52 projects across 24 states to reduce the cost of clean hydrogen. According to the DOE, clean hydrogen is set to play a vital role in reducing emissions from the most energy-intensive and polluting sectors of the economy.

For example, Airbus is testing the use of hydrogen fuel cells to generate electricity to power aircraft that fly with almost zero emissions. Airbus’ ZEROe project hopes to bring the world’s first hydrogen-powered commercial aircraft to market by 2035. Flight testing of the fuel-cell propulsion system on an Airbus 380 is scheduled for 2026.

Decarbonizing aviation with sustainable aviation fuel

The airline industry uses about 20 billion gallons of jet fuel every year, and globally, aviation accounts for 2% of all CO₂e and 12% of CO₂e from transportation, according to the DOE. Sustainable aviation fuel reduces emissions from air transportation, and when blended with conventional aviation fuel, is compatible with today’s aircraft and infrastructure. Depending on the feedstock and blend, SAF can reduce aviation’s CO₂e by up to 80%.

There are several pathways to making SAF, based on various feedstocks. These include sustainably sourced renewable waste such as cooking oil and animal fat; biomass such as agricultural and forest wastes and solid municipal wastes; and power-to-liquid SAF made from captured CO₂.

“Sustainable Energy Generation From Textile Biowaste and Its Challenges,” a paper published in 2022 by Shahjalal Khandaker, Ph.D., and others reports that waste from the textile industry could also be a significant source of biomass for fuel.

LanzaJet, a sustainable-fuels technology company spun out of LanzaTech in 2020, converts ethanol to SAF from any source of low-carbon ethanol, including biomass, industrial waste, municipal solid waste and CO₂. The company’s recently opened Freedom Pines facility in Soperton, Ga., supported by the DOE’s Bioenergy Technology Office, will produce 9 million gallons of SAF and 1 million gallons of renewable diesel in its first year of operation.

LanzaJet and Tadweer (Abu Dhabi Waste Management Company) are cooperating on a feasibility study to initiate SAF production from municipal and commercial solid waste. The hope is that up to 350,000 metric tons (385,809 U.S. tons) of hard-to-recycle municipal and commercial solid waste can be transformed into 200,000 metric tons (220,462 U.S. tons) of ethanol per year.

Renewable energy is a growth industry, accounting for 90% of all new electricity installed worldwide each year. While it’s the early days, there are opportunities for the textile industry to be involved.

A battery in a balloon

A company called Energy Dome, based in Milan, Italy, has developed a thermodynamic method of long-duration energy storage in a “battery” that uses CO₂ stored in a huge fabric dome, like a balloon, made of PVC-coated polyester. Energy from a local grid or nearby solar farm compresses the CO₂ into a liquid during the day. At night, the liquid CO₂ expands back into gas, driving a turbine that produces electricity and sends it back to the grid.

Energy Dome has its first U.S. installation planned for 2026 in Columbia County, Wisc., with Alliant Energy, and it has recently opened an office in Boston with a “growing ambition to decarbonize the world with our CO₂ Battery™ technology.” 

Debra Cobb is a freelance writer with expertise in the textiles industry. She is based in North Carolina.

To view the original article from Fabric Architecture Magazine, click here.

September 6, 2024

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