Note: Descriptions are shown in the official language in which they were submitted.
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TITLE OF THE INVENTION
PYRAMIDAL WALL SECTIONS
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR
DEVELOPMENT
N/A
BACKGROUND OF THE INVENTION
Various embodiments relate generally to modular wall systems, methods, and
devices
II) and, more specifically, relate to wall sections that can be used to
create walls for a pyramidal-
shaped structure.
This section is intended to provide a background or context. The description
may
include concepts that may be pursued, but have not necessarily been previously
conceived or
pursued. Unless indicated otherwise, what is described in this section is not
deemed prior art
to the description and claims and is not admitted to be prior art by inclusion
in this section.
The ability to create structures quickly can be very important for effective
emergency
response. Additionally, having materials which are lightweight and space-
efficient allows for
quick deployment in remote locations.
BRIEF SUMMARY OF THE INVENTION
The below summary is merely representative and non-limiting.
The above problems are overcome, and other advantages may be realized, by the
use
of the embodiments.
In a first aspect, an embodiment provides a solar panel assembly. The solar
panel
assembly includes a mounting post and at least three triangular shaped panels.
Each triangular
shaped panel is a solar panel responsive to a first spectrum of light and
transparent to a
second spectrum of light. The solar panel assembly also includes at least
three hinges. For
each triangular shaped panel, an associated hinge connects the triangular
shaped panel to the
mounting post. The at least three triangular shaped panels can move between a
flat
configuration (e.g., along a single plane) and an inverted pyramid
configuration.
In a further embodiment of the solar panel assembly, the at least three
triangular shaped
panels form a first solar panel layer, and the solar panel assembly also
includes one or more
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additional solar panel layers. Each of the additional solar panel layers being
responsive to an
associated spectrum of light.
In another aspect, an embodiment provides wall section which has a shell
defining a
plurality of pyramidal shapes. Each pyramidal shape has at least three
triangular sides. The
wall section includes at least one solar panel assembly as described above
disposed in an
associated pyramidal shape. An angle of the at least three triangular sides
with respect to the
base range between 50 and 85 .
In a further aspect, an embodiment provides a solar panel assembly. The solar
panel
assembly includes a mounting post and at least three triangular shaped panels.
Each triangular
II) shaped panel is a solar panel responsive to a first spectrum of light
and transparent to a
second spectrum of light. The solar panel assembly also includes an energy
storage
component. The energy storage component and the at least three triangular
shaped panels
define an inverted pyramid configuration where the energy storage component is
located in a
first portion of the inverted pyramid configuration and the at least three
triangular shaped
panels is located in a second, exterior facing portion of the inverted pyramid
configuration
(e.g., where the energy storage component is in the point of the pyramid shape
and the shaped
panels are in the portion nearest the base).
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
Aspects of the described embodiments are more evident in the following
description,
when read in conjunction with the attached Figures.
Figure 01 shows a pyramid mold core in accordance with an embodiment.
Figure 02 shows a carbon fiber sheet sized to the pyramid mold core.
Figure 03 shows the carbon fiber sheet after it has been vacuum formed to the
pyramid
mold core.
Figure 04 shows a male conductive frame.
Figure 05 shows a close-up of a section of the male conductive frame.
Figure 06 shows an outer shell section of the male conductive frame.
Figure 07 shows ball socket detail of the outer shell section for a panel rack
plug.
Figure 08 shows a first insulative layer of the male conductive frame.
Figure 09 shows a first conductive layer of the male conductive frame.
Figure 10 shows contact detail of the first conductive layer.
Figure 11 shows a second insulative layer of the male conductive frame.
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Figure 12 shows a second conductive layer of the male conductive frame.
Figure 13 shows a bird bone section of the male conductive frame.
Figure 14 shows an alternate cross section of the male conductive frame.
Figure 15 shows connector detail of the male conductive frame.
Figure 16 shows male frame connector tabs for a first conductive layer of the
male
conductive frame.
Figure 17 shows male frame connector tabs for second conductive layer of the
male
conductive frame.
Figure 18 shows the frame positioned with the pyramid mold core.
Figure 19 shows "keyhole" slots in carbon fiber sheet.
Figure 20 shows close-up detail of the "keyhole" slots.
Figure 21 shows the carbon fiber sheet preparing to wrap around the frame.
Figure 22 shows the outside edges of the carbon fiber sheet pulled up,
exposing the "foot
print" of the housing.
Figure 23 shows two vents cut into the carbon fiber sheet.
Figure 24 shows a detail of the vents.
Figure 25 introduces the clamp base.
Figure 26 introduces four slide action slides.
Figure 27 shows the slide action slides positioned on the clamp base.
Figure 28 shows the inline clamps in position on the clamp base.
Figure 29 introduces the inline clamp hardware.
Figure 30 shows the clamp fixture in position with handles down and open.
Figure 31 shows the inline clamps with handles up, closing against the slide
action
slides.
Figure 32 shows the clamping action against the carbon fiber sheet into a boss
on the
male ¨A¨ conductive frame.
Figure 33 shows a close-up detail of the area affected by the clamping action.
Figure 34 shows a close-up detail of area where the carbon fiber wraps over
the top of
the male conductive frame and back onto itself.
Figure 35 shows the carbon fiber sheet completely wrapped over itself.
Figure 36 shows circular cutouts into the top layer of the carbon fiber sheet.
Figure 37 introduces a locking post.
Figure 38 reveals the bottom side of the locking post.
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Figure 39 shows all four locking posts in position.
Figure 40 shows the wrap trimmed to expose the post slots.
Figure 41 shows wrap trimmed to expose bosses with ball socket detents.
Figure 42 shows one set of three oval slots cut into the second layer of the
carbon fiber
sheet.
Figure 43 shows a detail of the profile of the oval slots on top of the
"keyhole" slots.
Figure 44 shows a complete male side wall and bosses.
Figure 45 shows the male side wall oriented to show the grooves.
Figure 46 shows the reverse (top) side of a male side wall.
it) Figure 47 shows a cutaway view of a solar panel prepared to be inserted
into a male side
wall.
Figure 48 shows the cutaway view along the long, diagonal edge.
Figure 49 shows the solar panel in place in the male side wall.
Figure 50 shows a cropped detail of two solar panel posts in the male side
wall.
Figure 51 shows a solar panel post locked in position in a "keyway" slot.
Figure 52 shows a detail of the solar panel locked in position.
Figure 53 shows a module of four solar panels in relative position.
Figure 54 shows a solar panel module locked in place in a male side wall.
Figure 55 shows a connection rack.
Figure 56A shows a cutaway view of the connection rack.
Figure 56B shows the extracted circuits of the connection rack.
Figure 57 shows a connection rack oriented to join a male side wall.
Figure 58 shows a connection rack locked in place with a male side wall.
Figure 59 shows a cutaway detail of a detent socket on a connection rack.
Figure 60 shows a cutaway detail of a conductive lead on the solar panel post
locked into
a detent socket.
Figure 61 shows a cutaway of a connection rack.
Figure 62 shows a detail of a cross section of the ball socket snap fits.
Figure 63 shows a view of the ball joints locked into the ball snap fits.
Figure 64 introduces the remaining connection racks.
Figure 65 shows all connection racks locked into place.
Figure 66 shows a second module of solar panels separated and ready to be
locked into
place.
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Figure 67 shows the second module of solar panels locked into place.
Figure 68 shows a completed assembly of a male solar panel section from the
solar
panels side.
Figure 69 shows a close-up view of a solar panel.
Figure 70 shows exaggerated detail of the casing of the panel.
Figure 71 shows a female ¨B¨ wall section from the connection rack side.
Figure 72 shows a detail of the combined female connector ends.
Figure 73 shows a detail of the connector ends of the female first conductive
layer.
Figure 74 shows a detail of the female second insulative layer.
Figure 75 shows a detail of the connector end's female second conductive
layer.
Figure 76 shows a detail of the isolated connector ends of the female first
conductive
layer.
Figure 77 shows a detail of the isolated female second insulative layer.
Figure 78 shows a detail of the isolated connector ends of the female second
conductive
layer.
Figure 79 shows male ¨A¨ and female ¨B¨ wall sections in relative position.
Figure 80A shows a detail of the ¨A¨ male connector ends and ¨B¨ female
connector
ends.
Figure 80B shows a close-up of an 0-ring groove.
Figure 80C shows a cross section of the corner exposing the 0-ring groove and
the 0-
ring.
Figure 81 shows male ¨A¨ and female ¨B¨ wall sections locked in place in a
modular
array.
Figure 82 shows alternate view of male ¨A¨ and female ¨B¨ wall sections locked
in
place in the modular array.
Figure 83 shows a cropped detail of the junction of ¨A¨ & ¨B¨ sections which
folin a
post slot.
Figure 84 shows a cropped detail of a laterally exploded junction of ¨A¨ & ¨B¨
sections.
Figure 85 shows a cutaway dimetric view of the laterally exploded ¨A¨ &
¨B¨junction
with a locking post from a backing wall section.
Figure 86 shows an alternate view of the laterally exploded ¨A¨ & ¨B¨ junction
and
locking post.
Figure 87 shows an ¨A¨ & ¨B¨junction joined together.
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Figure 88 shows a locking post secure in the post slot.
Figure 89 shows a rotated view of the locking post secure in the post slot.
Figure 90 shows the modular array from the solar panel side.
Figure 91 shows a view of the modular array and a backing wall section.
Figure 92 shows a view of the modular array with the capacitor wall section in
position.
Figure 93A shows the body of a magnetic securing post.
Figure 93B shows an exploded view of a magnetic securing post.
Figure 93C shows a magnetic securing post with the locking magnet.
Figure 93D shows a magnetic securing post with a view of the rectangular thru
hole.
Figure 94 shows a view of a magnetic securing post in view ready to assemble.
Figure 95A shows a magnetic insertion tool.
Figure 95B shows the magnetic securing post slid into position on the magnetic
insertion
tool.
Figure 95C shows another view of the magnetic securing post on a magnetic
insertion
tool.
Figure 96 shows a cropped view of the cross section of an ¨A¨ & ¨B¨ junction
and the
insertion tool with a magnetic securing post loaded on it.
Figure 97 shows a small steel retaining disk and a steel recess in the post
slot.
Figure 98 shows the small steel retaining disk bonded in the steel recess.
Figure 99 shows a magnetic securing post locked in position.
Figure 100 shows a modular array locked with a sample structural backing.
Figure 101 shows a capacitor wall section.
Figure 102 shows the cathode contact side of a capacitor cell.
Figure 103A shows the anode contact side of a capacitor cell.
Figure 103B shows a rotated capacitor cell.
Figure 104A shows an insulated cover sectioned to reveal a honeycomb anode, an
LED
and a cathode LED channel.
Figure 104B is a cropped, close-up view of the sectioned, insulated cover.
Figure 104C shows an exploded view of a capacitor cell.
Figure 104D shows a cropped, detailed area of a section of the insulated cover
and
honeycomb anode.
Figure 104E shows the insulated cover with the anode conductive posts showing
through
the capacitor cover holes.
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Figure 105A shows an insulated cover separated from a honeycomb anode.
Figure 105B shows the reverse side of the insulated cover joined with a
honeycomb
anode.
Figure 105C is a section view of an LED and the cathode LED channel.
Figure 105D is a section view of tapered cover bosses on an insulated cover.
Figure 105E is a cropped detail of one covered boss and the cathode LED
channel.
Figure 105F shows the honeycomb anode separated from the insulated cover.
Figure 105G is shows the LED in the exploded view of Figure 105F.
Figure 106 shows the indicator LED.
Figure 107A shows a capacitor cell casing and a honeycomb cathode.
Figure 107B shows the capacitor cell casing and the honeycomb cathode
separated.
Figure 107C shows a cropped detail of a cathode conductive post.
Figure 107D shows a partially assembled capacitor cell.
Figure 107E shows a cropped detail of the capacitor cell.
Figure 107F shows another view of the capacitor cell.
Figure 108A shows a cropped detail of the top of the capacitor cell.
Figure 108B shows another view of the top of the capacitor cell.
Figure 109 shows an exploded view of the capacitor cell.
Figure 110 shows a capacitor rack removed from a complete (male) capacitor
wall
section.
Figure 111 shows a capacitor rack.
Figure 112 shows the capacitor rack circuit.
Figure 113 shows a circuit contact to the cathode.
Figure 114 shows a hatch on the tip of a cathode connection post.
Figure 115 shows a detail of cathode connection post and the capacitor rack.
Figure 116 shows an example of a solar panel wall in a pyramid wall frame.
Figure 117 shows the backside of a pyramid wall frame.
Figure 118 shows the U-shaped base of the pyramid wall frame.
Figure 119 shows pyramid frame comers added to the frame.
Figure 120 shows top half female sections inserted at the bottom of the frame.
Figure 121 shows the frame with one male side ¨A¨ wall section and two female
side ¨
B¨ wall sections.
Figure 122 shows the frame with two half female sections.
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Figure 123 shows the frame with the remainder of sections.
Figure 124 shows the frame with the capacitor wall.
Figure 125 shows the frame with the frame cover.
Figure 126 shows the frame with a capacitor shield.
Figure 126A shows the capacitor shield.
Figure 127 shows the frame with multiple capacitor shields.
Figure 128 shows another view of the pyramid wall frame.
Figure 129 shows the bottom of the pyramid wall frame with a frame cover.
Figure 130 shows the assembly with the solar panel wall.
it) Figure 131 shows the frame with pyramid frame corners.
Figure 132 shows the pyramid wall frame with a top cover.
Figure 133 shows a moderately angled pyramid with a rhombus or diamond shaped
base.
Figure 134 shows a shallow angled pyramid with a diamond shaped base.
Figure 135 shows a steep pyramid with a diamond shaped base.
Figure 136 shows the geometry of inverted pyramids of uneven length sides.
Figure 137 shows airflow on the underside of panels and their internal
reflectivity.
Figure 138 shows an exploded view of a cross panel assembly.
Figure 139 shows a flattened cross panel assembly introducing a second set of
panels.
Figure 140 shows an exploded view of the cross panel mounting post.
Figure 141 shows a cross section of the cross panel mounting post.
Figure 142 shows the topside of a transparent honeycomb panel and its hinge.
Figure 143 shows a close-up of the section view of its hinge.
Figure 144 shows a section view of the cross panel assembly in the flattened
position
Figure 145 shows a section view of the cross panel assembly folded up.
Figure 146 isolates the hinges in the flat position and the first layer of
wiring in the cross
panel mounting post.
Figure 147 adds the second layer of wiring in the cross panel mounting post.
Figure 148 shows the hinges in the folded position and the exposed leads of
the wiring.
Figure 149 shows a partially folded assembly, highlighting an
electroluminescent
coating on the back of the first layer of panels.
Figure 150 shows a plan view of a transparent honeycomb panel.
Figure 151 shows a cropped detail of the connection end of a honeycomb panel.
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Figure 152 shows further detail of the honeycomb panel's connection, with a
section
view of the conductive contacts.
Figure 153 shows a fully assembled and folded cross panel, highlighting the
electroluminescent side of one panel.
Figure 154 shows a screw conveyor for to handle plastic pellets for 3D
printing.
Figure 155 shows a robotic 3D printing system.
Figure 156 shows detail of an exploded view of a robotic arm and extruder.
Figure 157 shows a setup for vacuum forming thermoplastic sheets.
Figure 158 sections the tubing and mold in the vacuum forming process.
Figure 159 details a section view of the tubing, mold and mold vents in the
vacuum
forming setup.
Figure 160 introduces a thermoplastic sheet into the vacuum forming setup.
Figure 161 shows a vacuum/thermoformed sheet lifted off of the mold.
Figure 162 shows an exploded view of a thermoformed formed pyramid wall
assembly.
Figure 163 shows the backside of a thermoformed pyramid wall assembly.
Figure 164 shows the front side of a thermoformed pyramid wall assembly.
Figure 165 shows a setup to injection mold a pyramid wall section.
Figure 166 shows a pyramid wall section ejected from the mold.
Figure 167 shows the backside of an injection molded pyramid wall section.
Figure 168 shows two pyramid wall panel sections back to back.
Figure 169 shows a detail of the connecting features between the panels.
Figure 170 shows a breakaway section of the sandwiched walls with foam
inserted
between them.
Figure 171 shows a single, diamond Pyramid Wall section above a Wall Socket,
mounting screws and an Aligning Template.
Figure 172 shows a close-up of an exploded view of a sectioned Wall Socket
assembly.
Figure 173 shows a close-up of a sectioned Wall Socket assembly aligned with a
Pyramid Wall.
Figure 174 adds a sectioned Aligning Template.
Figure 175 removes the sectioning from the close-up.
Figure 176 shows a cropped, exploded view of a full Pyramid Wall section, Wall
Sockets and Aligning Template.
Figure 177 removes the Pyramid Wall section and shows a close-up.
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Figure 178 shows an exploded view of Cross Panels with post for stacking
"Flower"
panels or "Petals" into a cell.
Figure 179 adds a second level of panels to the assembly.
Figure 180 shows an exploded view of the Flower Post.
Figure 181 shows a section view of the Flower Post.
Figure 182 details a section view of the Flower Post Cap, its snap fits and
the snap fit
sockets in the post.
Figure 183 shows the first level of internal wiring in the Flower Post as it
connects to the
hinges, as well as the serial connection to the other levels of panels.
Figure 184 shows internal wiring in the Flower Post (with the post's body
removed).
Figure 185 shows panels connected to the wiring, with the post's body and
panels in the
foreground removed for clarity.
Figure 186 shows a completed, stacked 'Flower' assembly, with the Cross Panels
in the
flattened position.
Figure 187 shows the Cross Panels folded into a pyramid shape, making a
complete
Flower Panel Cell.
Figure 188 shows an alternate stacking setup with a horizontal panel and Post
connections.
Figure 189 shows a section view of a completed stacking of horizontal panels,
with the
Cross Panels in the flattened position.
Figure 190 removes the section view of the stacked panels.
Figure 191 shows an alternate section view of the stacked, horizontal panels
and the
cross panels folded up into a pyramid shape.
Figure 192 shows a completely assembled and folded Horizontal Flower Panel
Cell.
Figure 193 shows a section view of a concave, transparent cover over a panel
section
containing a horizontal flower petal assembly.
Figure 194 shows variations of transparent cover geometries including flat,
spherically
concave, oval concave and teardrop concave.
Figure 195 shows variations of transparent cover geometries including
spherically
concave with lens, spherically convex, oval convex and teardrop convex.
Figure 196 shows an alternate horizontal petal cell without a center post, one
panel and
hinge removed for viewing and a spherically concave transparent cover
overhead.
Figure 197 shows an exploded view of a locking hub assembly for the petal
cell.
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Figure 198 shows a section view of the locking hub.
Figure 199 shows the wiring within the locking hub and the connections to the
hinges.
Figure 200 shows a completely assembled horizontal flower panel assembly with
a
concave transparent cover.
Figure 201 shows an exploded view of a supercapacitor cell.
Figure 202 shows the positive and negative leads in the cell.
Figure 203 shows a connection rack connected to the leads and a sectioned cell
casing.
Figure 204 shows the introduction of positive, honeycomb layers.
Figure 205 shows all positive layers.
Figure 206 shows a side view of all positive and negative layers, as well as
angled views
of its top and bottom.
Figure 207 shows a completed supercapacitor module upside down.
Figure 208 shows an exploded view of a hybrid capacitor, post-less flower
panel cell.
Figure 209 shows a section view of a supercapacitor module with variations of
flower
panel cells on top.
Figure 210 shows the same module with a sectioned cover and a concave dimple
over
one cell.
Figure 211 shows a fully assembled tractor trailer with the Pyramid Wall
System.
Figure 212 shows an exploded views of the trailer frame, top and side Pyramid
Wall
sections and details of the wall section's front and back.
Figure 213 shows an exploded views of front and back transparent, dimpled wall
covers
with the cab added.
Figure 214 shows an exploded view of the top and side transparent, dimpled
covers.
Figure 215 shows an exploded view of the top transparent dimpled cover.
Figure 216 shows a section view of the trailer.
Figure 217 shows the front end of a sectioned tractor trailer.
Figure 218 shows the front end of a complete tractor trailer with Pyramid Wall
System.
Figure 219 shows an exploded view of a sound wall section within an "H-Frame".
Figure 220 shows an assembled sound wall section.
Figure 221 shows a sound wall section with a breakaway view, exposing a foam
or pellet
filled interior.
Figure 222 shows a stretch of sound wall barrier.
Figure 223 shows a Pyramid Structure.
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Figure 224 shows an exploded view of one triangular sidewall of a Pyramid
Structure.
Figure 225 shows a detail of a triangular sidewall positioned to engage base
slots.
Figure 226 shows a completed triangular sidewall from another angle, ready to
be
inserted in base slots and onto a base.
Figure 227 shows two views of a completed triangular sidewall engaged in base
slots
and ready to be connected to a base.
Figure 228 shows one triangular sidewall inserted into a completed base
section, with
frame members in position.
Figure 229 shows a completed Pyramid Structure with a cap to be inserted.
Figure 230 shows a building with sides covered by Pyramid Wall sections and
Pyramid
Structure Bases on the roof
Figure 231 shows partly assembled Pyramid Wall Structures on the roof
Figure 232 shows a building with Pyramid Wall sections on its sides and four
Pyramid
Wall Structures on its roof.
Figure 233 shows a self-contained Pyramid Structure on a two-axis tracking
system.
Figure 234 shows an alternate building setup, with sides and roof covered with
a single
layer Pyramid Wall System.
Figure 235 shows a cropped detail of a Wind Skirt surrounding a Pyramid Wall
Section.
DETAILED DESCRIPTION OF THE INVENTION
[ BLANK ]
The non-limiting embodiment shown in the figures demonstrate a sequence of
manufacturing and assembly steps involved in making diamond wall sections.
Various elements
of this embodiment may be described with specific measurements. In other
embodiments, the
dimensions of the elements may be adjusted accordingly, for example, to
produce smaller or
larger diamond wail sections. In further embodiments, the sequence of
manufacturing and
assembly steps may be reordered and various steps may be combined and/or
omitted.
The pyramid shape has many benefits including strength and increased surface
area. One
main idea behind the pyramid wall system is threefold:
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1) to create a lightweight, inexpensive, modular system that is self-
sustaining with
power.
2) to increase its capacity for energy storage and efficiency of its solar
panels. The
pyramid configuration of solar panels gives them 38% more surface area to be
exposed to solar energy.
3) the exposed inside/out pyramid pattern reduces wind resistance on the
sidewalls of
tractor-trailers, similar to the idea of dimples on a golf ball used to extend
flight. The
reduced drag alone can save at least 11% annual fuel costs per vehicle.
The pyramid wall system is adaptable to structural frameworks that form many
different
it) geometric shapes (polyhedral) including, but not limited to,
tetrahedrons (pyramids with 3 sides
and a base), right pyramids (4 sides and a base), cubes, rectangular cuboids,
etc. Wall sections
may be sectioned further to form the boundary edge of a frame to support each
face of the
structure.
The pyramid mold core 100 shown in Figure 01 is the underlying form used to
produce
the carbon fiber housing. It may be 3D printed in thermoplastic using a
process called Fused
Filament Fabrication (FFF), also called Fused Deposition Modelling (FDM). In
this process,
plastic filament is fed into an extruder which melts and feeds it through a
nozzle. The filament
may have composite fibers added as well for additional strength and
dimensional stability. Data
from a 3D model is converted into code which determines the path of the
extruder head, the
speed of the path, flow rate of material and temperature. The extruder head is
attached to a dual
gantry setup, allowing servo motors to position it over a level build plate at
various points along
the X, Y & Z axis. There may be two or more extruder heads, each controlled
independently.
The pyramid mold core 100 may be partially hollow with a latticed interior, or
solid
filled and/or electroplated for rigidity. The "foot print" 110 of the housing
is diamond shaped,
just under 29" x 18" diagonally and 2" thick. It supports four sets of pyramid
shaped bosses 120
which are just under 5" high from each base to their apices. The entire mold
core 100 can be
made in one piece.
Figure 02 shows a carbon fiber sheet 200 used to make the housing. Carbon
fiber or its
equivalent has several advantages over conventional materials and construction
methods. It is
lighter, stronger and more durable than wood or metal and can be formed into
shapes not
possible with these materials. It may be between 1 mm and 1.75 mm thick. The
carbon fiber
sheet 200 may be cut into a pattern based on where the seams are to be located
and/or to provide
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openings when positioned. In Figure 03 the carbon fiber sheet 200 is vacuum
formed to take on
the shape of the pyramid mold core 100.
Figure 04 shows a male conductive frame 400. This frame 400 creates a wireless
unit
and reduces the chance of long term damage by being embedded in the composite
housing. This
frame 400, referred to as a male ¨A¨ conductive frame, follows the contour of
the pyramid
walls. As shown in Figures 05-17, the frame 400 is 3D printed with dual
materials; the first
being an insulative thermoplastic which forms the outer shell (500), as well
as the first and
second insulative layers (which alternate between the conductive layers). The
second material
may be conductive, such as a graphene infused thermoplastic as one non-
limiting example. It
forms the first and second conductive layers as well as the "bird bone" core
1300, a hollow light
weight internal structure to allow airflow.
This bird bone core 1300 is a structural component providing increased
strength at a
fraction of the weight. The bird bone core 1300 also provides airflow (e.g.,
an inert gas flow)
which allows a positive ionic current as low pressure gas flows through the
lattice increasing
current flow. As described below, the bird bone core 1300 also provides a
conductive path for
sections with solar panels 1800.
In one non-limiting embodiment, the outer shell 500 has post slots 510 along
the top face
to allow locking posts 1660 to connect the diamond sections. This design may
be used where
space between back to back wall sections is restricted.
In another non-limiting embodiment, post/slot combinations can be part of the
outer
shell 500 when space is not as restricted. Post slots 510 would be replaced
with a raised
cylindrical post that has a blind channel cut into the side. The profile of
the channel has a "T"
shaped cross section with a radiused inner face. (See Figures 14, 40, 83, 87,
88 & 97 for original
post slots 510). Locking posts 1660 may be replaced with shouldered
cylindrical bosses to create
a "T" shaped post to fit inside these channels. (See Figures 36-39, 85, 87 &
88 for original
locking posts 1660).
In this non-limiting embodiment, the frame 400 is greatly simplified by
removing slot
features that cut into various layers of conductors and insulators (see Figure
14). The "V" shaped
bosses 520 and grooves 530 along the sides help with alignment and securing.
Four sets of ball
socket bosses 540 connect the panel rack plugs to the first and second
conductive layers. Each
corner along the long diagonal has open rectangular slots 550 between
connector tabs 560 for
the first conductive layer 900 and connector tabs 570 for the second
conductive layer 1200. The
frame 400 is then placed over the raw carbon fiber material 200.
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Figure 05 highlights a cross section 500 of the frame 400. Figures 06-13
isolate various
components and features of this cross section.
Figure 06 shows the outer shell section 600 having half of the "V" profile of
this cross
section. Here, the ball socket bosses 540 and ball socket snap fits 700 are
shown. They may be
made of an insulative thermoplastic.
Figure 07 shows details of one of the ball socket snap fits 700 used to secure
the ball
joints 2150 of the panel rack plugs (see Figure 61). They have a spherical
cavity with three relief
slots to help conform to the ball shaped plug and then engage the ball shaped
plug when in
place.
Figure 08 shows the first insulative layer 800 which is the same material as
the outer
shell. It can be differentiated because it follows the contour of the first
conductive layer (see
Figure 9). In this non-limiting embodiment, the material is approximately
1/32" thick.
Figure 09 shows the first conductive layer 900 which may be printed with a
graphene
infused/embedded thermoplastic (or equivalent). This layer 900 conducts a
negative charge,
terminates with a conical shaped receptacle 1000 and may be approximately
1/32" thick in this
non-limiting embodiment.
In Figure 10, the details are shown of the conical shaped receptacle 1000 for
the plug tip.
This is the electrical contact for the first conductive layer 900 when the
ball joint 2150 (see
Figure 61) is in place in the ball socket snap fits 700 inside of their ball
socket bosses 540.
The second insulative layer 1100, shown in Figure 11, is the same material as
the outer
shell 600 and the first insulative layer 800. This second insulative layer
1100 is sandwiched
between the first and second conductive layers 900, 1200 and, in this non-
limiting embodiment,
is approximately 1/32" thick.
Figure 12 shows the second conductive layer 1200. This layer 1200 is the same
material
as the first conductive layer 900 except that it conducts a positive charge
and terminates with a
conical shaped receptacle 1210. It can be considered a shell of the "bird
bone" core 1300 (shown
in Figure 13) but is distinguished because it follows the contour of the
second insulative layer
1100. In this non-limiting embodiment, the second conductive layer 1200 is
approximately
1/32" thick.
The bird bone section 1300 of Figure 13 is also the same material as the first
and second
conductive layers 900, 1200 and carries a positive charge. The shape of this
core 1300 can be
hollow and organic, like a bird bone in order to be lightweight and to offer
some structural
reinforcement while allowing airflow.
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Figure 14 shows an alternate cross section of the layers of the frame in an
end view.
Starting at the center 1400, the "bird bone" 1300 is positively charged,
surrounding the center
1400 is the second conductive layer 1200 (positively charged), then the second
insulative layer
1100, then the first conductive layer 900 (negatively charged), then the first
insulative layer 800
and finally the shell 600 on the outside. Post slots 510 are shown at the top
of the image. (Note
that in this example, the second insulative layer 1100 is not continuous, for
example, due to
limited space).
Figure 15 shows a cropped view of a male ¨A¨ conductive frame 400, with open
rectangular slots 550 at the corners. These slots are openings in the
conductive "bird bone" core
1300 to allow the flow of low pressure gas between panel sections when they
are connected.
Figure 16 shows an isolated view of the connector tabs 560 for the first
conductive layer 900.
The outer border of this layer and these tabs is the first insulative layer
800. Figure 17 shows an
isolated view of the connector tabs 570 for the second conductive layer 1200.
The outer border
of this layer and these tabs is the second insulative layer 1100.
Figure 18 shows a male ¨A¨conductive frame 400 in position on a vacuum formed,
carbon fiber sheet 200. Figure 19 shows one set of three "keyhole" slots 1500
cut into the first
layer of a vacuum formed, carbon fiber sheet 200. Figure 20 shows a detail of
the profiles of the
"keyhole" slots 1500. The narrow section of each slot 1500 retains the
shoulder of a post 1810
on the back of a solar panel 1800, when it is put in position. There are four
sets of slots 1500 for
each pyramid shaped boss and four pyramid shaped bosses total for each carbon
fiber housing.
Figure 21 shows the outside edges of the carbon fiber sheet 200 preparing to
wrap around the
frame 400 and on top of itself. Figure 22 shows the outside edges of the
carbon fiber sheet 200
pulled up, exposing the "foot print" 110 of the housing to allow clearance for
the clamp fixture
1600.
Figure 23 shows two vents 1700 being cut into the carbon fiber sheet 200 at
the long
diagonal corner (opposite corner obscured in this view). These cuts are to
allow clearance for the
open rectangular slots 550, the connector tabs 560 & 570. Figure 24 shows a
detail of the vents
1700.
Figure 25 introduces the clamp base 1610 and Figure 26 introduces four slide
action
slides 1620 and Figure 27 shows the slide action slides 1620 positioned on the
clamp base 1610.
Figure 28 shows the inline clamps 1630 in position on the clamp base 1610.
Figure 29
introduces the inline clamp hardware 1640. One of the four clamps has the
hardware already in
position. Figure 30 shows the clamp fixture 1600 in position with handles down
and open.
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Figure 31 shows the inline clamps 1630 with handles up, closing against the
slide action
slides 1620. Figure 32 shows a detail of the clamping action against the
carbon fiber sheet 200
into a V shaped boss 520 on the male ¨A¨ conductive frame 400.
Figure 33 shows a close-up detail of the area affected by the clamping action
including
the carbon fiber sheet 200 and the V shaped boss 520. Figure 34 shows a close-
up detail of the
area where the carbon fiber sheet 200 wraps over the top of the male
conductive frame 400 and
back onto itself in a second layer.
Figure 35 shows the carbon fiber sheet 200 completely wrapped over itself
completing
the second layer. Figure 36 shows circular cutouts 1650 into the top layer of
the carbon fiber
to sheet 200, but not into the first layer. This is to create a recess for
the locking posts 1660 to be
bonded in.
Figure 37 introduces a locking post 1660. Figure 38 reveals the bottom side of
a locking
post 1660. These four faces 1670 and/or the exposed faces of the circular
cutouts 1650 have glue
applied there to bond the posts 1660. Figure 39 shows all four locking posts
1660 in position.
Figure 40 shows the wrap trimmed to expose the post slots 510 and Figure 41
shows the
wrap trimmed to expose ball socket bosses 540 with ball socket snap fits 700.
Figure 42 shows one set of three oval slots 1820 cut into the second layer of
a vacuum
formed, carbon fiber sheet 200. Figure 43 shows a detail of the profile of the
oval slots 1820 on
top of the "keyhole" slots 1500. These slots 1820 are aligned with the
"keyhole" slots 1500 on
the first layer and provide a stop against the head of a post 1810 on the back
of a solar panel
1800 when it is put in position. There are four sets of slots 1820, 1500 for
each pyramid boss
120 and a total of four pyramid bosses 120 for each carbon fiber housing.
Figure 44 shows a complete male side wall 1900 (minus solar panels) and V
shaped
bosses 520. Figure 45 shows the male side wall 1900 (minus solar panels)
oriented to show the
V shaped grooves 530.
Figure 46 shows the top side (inside) of a male side wall 1900 (minus solar
panels)
before the insertion of solar panels 1800.
Figure 47 shows a single solar panel 1800 prepared to be inserted into a male
side wall
1900 with a cutaway of the face it is sliding into and an adjacent face.
Figure 48 shows the
cutaway view in Figure 47 but along the long, diagonal edge (normal to a plane
that bisects the
short diagonal edges). Figure 49 shows the single solar panel 1800 in place
into a male side wall
1900 with the same cutaway view as in Figure 48.
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Figure 50 shows a cropped detail of a cutaway of two solar panel posts 1810
with one
post 1810 inserted at the wide section of a "keyway" slot 1500 and its
shoulder resting at one
end of an oval slot 1820. Figure 51 shows a solar panel post 1810 locked in
position with its
shoulder on top of the narrow section of a "keyway" slot 1500 and pushed
against the opposite
end of an oval slot 1820. Figure 52 shows a detail of both posts 1810, as well
as a reinforcement
tab 1830 on the back of a solar panel 1800 locked in position.
Figure 53 shows a module 2000 of four (4) solar panels 1800 in relative
position and
Figure 54 shows a solar panel module 2000 locked in place in a male side wall
1900.
Figure 55 shows a connection rack 2100 used to join a solar panel module 2000
and
connect it to the first conductive layer 900 and the second conductive layer
1200. These racks
2100 are beneficial because they eliminate exposed wires and, if damaged, can
be easily
replaced. Because they are arranged in parallel, individual racks 2100 can be
replaced without
interrupting current flow.
Figure 56A shows a cutaway view of a connection rack 2100. It shows its
connection
rack body 2110, solar rack positive circuit 2120, solar rack negative circuit
2130, positive lead
2160 and negative lead 2170. Figure 56B shows two views of the extracted
circuits for clarity.
They are solar rack positive circuit 2120 and positive lead 2160, in the left
view, and, in the right
view, solar rack negative circuit 2130 and negative lead 2170.
In one non-limiting example, the connection rack 2100 will consist of metal
conductive
circuits 2120, 2130 overmolded with a thermoplastic body. In another non-
limiting example, the
components may be 3D printed with dual extruder heads. In this process, the
body 2110 is
printed using an insulative thermoplastic, while a second material will make
the conductive
circuits 2120, 2130, possibly using a graphene infused thermoplastic similar
to the male
conductive frame 400. In a further, non-limiting example, the body 2110 is 3D
printed or
molded in sections and locks in conductive wire.
Figure 57 shows a connection rack 2100 oriented to join a male side wall 1900.
Figure
58 shows the connection rack 2100 locked in place with the male side wall
1900. Figure 59
shows a cutaway detail of one of the eight (8) detent sockets 2190 on a
connection rack 2100.
The detent sockets 2190 are used to retain the bulbous tip of the conductive
lead on the solar
panel post 1810. In this image, the solar panel 1800 and its post 1810 are
hidden to reveal the
cavity of the detent socket 2190.
Figure 60 shows a cutaway detail (similar to Figure 59), where the bulbous tip
of a
conductive lead on the solar panel post 1810 is exposed as it is locked into a
detent socket 2130.
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Figure 61 shows a cutaway of a connection rack 2100. At the bottom is a detail
of the
ball joints 2150 that go into the ball socket snap fits 700 (see Figure 7).
These snap fits 700
house the exposed positive lead 2160 of the solar rack positive circuit 2120
as well as the
exposed negative lead 2170 of the solar rack negative circuit 2130.
Figure 62 shows a detail of the cross section of the ball socket snap fits 700
(with the
connection rack 2100 hidden) and the solar panel posts 1810 exposed.
Figure 63 shows a view (similar to Figure 60), but reveals the ball joints
2150 locked
into the ball snap fits 700 and a cutaway of the connection rack 2100 exposing
a solar panel post
1810 in place.
Figure 64 introduces the three (3) remaining connection racks 2100 to complete
the
backside of a solar panel section. Figure 65 shows all four (4) connection
racks 2100 locked into
place.
Figure 66 shows a second module of four (4) solar panels 2000 separated and
ready to be
locked into place. Figure 67 shows the second module of four (4) solar panels
2000 locked into
place. Figure 68 shows a completed assembly of a male solar panel section 2300
from the
exposed solar panels side.
Figure 69 shows a solar panel 1800 and the area to be detailed of a
transparent casing
1840 (which is shown in Figure 70). This casing consists of wave patterned,
refraction steps on
the outside surface of the panel 1800. In one non-limiting embodiment, the
cells on the
photovoltaic (PV) solar panel 1800 are 3D printed with multiple extruder
heads, each assigned a
different material. The first extruder prints an insulative backing. A second
prints a conductive
path for the bottom positive cell layer using conductive ink. A third prints a
positively "doped"
semi-conductive layer and a fourth prints a negatively doped semi-conductive
layer. The second
extruder can be reintroduced and prints a conductive path for the top negative
layer.
At various levels of the build, in one non-limiting embodiment, the print is
stopped to
insert components, restarted and then encapsulate parts which are combined
into an integrated
circuit or IC. This IC may be a junction box consisting of bypass and blocking
diodes in parallel
to prevent a back flow of current and to allow continuous electricity in case
an individual cell is
damaged. In another non-limiting embodiment, the entire IC subassembly can be
3D printed at
once using multiple extruder heads, each with a separate material in the same
fashion that the
cells are printed.
Figure 70 shows exaggerated detail of wave patterned, transparent, refraction
steps 1840
on the casing of the panel, as referenced in Figure 69. These steps increase
the surface area that
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is exposed to sunlight. In one non-limiting embodiment, this casing is
produced as an injection
molded component using an optical quality polymer and then polished. The edges
are then
bonded onto the top layer of the cell and complete the solar panel 1800. In
another non-limiting
embodiment, the casing is 3D printed using a different process, such as
Stereolithograhy (SLA),
and then polished to refine the refraction steps 1840.
Figure 71 shows a female ¨B¨ wall section 2400 from the connection rack side.
Figure
72 shows a detail of the combined female connector ends 2410. Figure 73 shows
a detail of the
connector ends of the female first conductive layer 2430. (A female first
insulative layer is
obscured).
Figure 74 shows a detail of the female second insulative layer 2440 and its
reinforced,
connective sheath 2450 on the right side. Figure 75 shows a detail of the
connector end's female
second conductive layer 2460.
Figure 76 shows a detail of the isolated connector ends of female first
conductive layer
2430. Figure 77 shows a detail of the isolated female second insulative layer
2440 and its
reinforced, connective sheath 2450 on the right side. Figure 78 shows a detail
of the isolated
connector ends of the female second conductive layer 2460.
Figure 79 shows male¨A¨ wall sections 2300 and female¨B¨ wall sections 2400 in
relative position from the connector side.
Figure 80A shows a detail of the ¨A¨ male connector ends (combined 550, 560
and
570), ¨B¨ female connector ends 2410, cutout vents 1700 at mating corners, V
shaped bosses
520, V shaped grooves 530 and 0-ring groove 580. Figure 80B shows a close-up
of an 0-ring
groove 580. This is used to seal the wall sections together and prevent
moisture from penetrating
either side. The groove surfaces may be coated with glue to reinforce the
seal. Figure 80C shows
a cross section of the corner exposing the 0-ring groove 580 and the 0-ring
590.
Figure 81 shows male 2300 ¨A¨ and female 2400 ¨B¨ wall sections locked in
place in a
modular array 2500 from the connector side view. Figure 82 shows alternate
view of male¨A¨
and female¨B¨ wall sections 2300, 2400 locked in place in the modular array
2500 from the
connector side view (here, normal to the underside face).
Figure 83 shows a cropped detail of the junction of ¨A¨ and ¨B¨ sections 2510
which
form a post slot 510. Figure 84 shows a cropped detail of a laterally exploded
junction of ¨A¨
and ¨B¨ sections 2510.
Figure 85 shows a cutaway dimetric view of the laterally exploded ¨A¨ and ¨B¨
junction 2510 with a locking post 1660 from a backing wall section oriented to
join the modular
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array 2500. Figure 86 shows an alternate view of the assembly in Figure 85,
normal to a plane
that bisects the short diagonal edges. Figure 87 shows an ¨A¨ and ¨B¨ junction
2510 joined
together. A locking post 1660 is oriented to insert into a post slot 510 and
join a backing wall
section to the modular array 2500. Figure 88 shows the locking post 1660
secure in the post slot
510, from a section view normal to a plane that bisects the short diagonal
edges and Figure 89
shows a section view rotated 90 from the orientation of Figure 88.
Figure 90 shows the modular array 2500 from the solar panel side.
Figure 91 shows a side view of a modular array 2500 and a backing wall
section. In this
non-limiting embodiment, this backing wall is to be a capacitor wall section
2900. Figure 92
II) shows a side section view along the long diagonal of a modular array
2500, with a capacitor wall
section 2900 in position.
In order to prevent back-to-back wall sections (such as modular array 2500 and
capacitor
wall section 2900) from sliding apart a magnetic securing post 3000 is used.
The body 3010 of
these posts 3000 is made out of thermoplastic and has a rare earth NdFeB
locking magnet 3020
bonded into it.
Figure 93A shows the body 3010 of a magnetic securing post 3000. Figure 93B
shows
an exploded view of a magnetic securing post 3000. At top is the body 3010 of
a magnetic
securing post 3000 and at the bottom is the rare earth NdFeB locking magnet
3020. Figure 93C
shows a magnetic securing post 3000 assembled with the rare earth NdFeB
locking magnet 3020
bonded in and its South Pole 3030 facing outward. Figure 93D shows the
magnetic securing post
3000 with a clear view of its rectangular thru hole 3050.
Figure 94 shows a view similar to Figure 92 with a magnetic securing post 3000
in view
and ready to assemble.
Figure 95A shows a magnetic insertion tool 3040. The tool body has a
rectangular
profile to prevent the magnetic securing post 3000 from wobbling and slides
into the rectangular
thru hole 3050 in the post's body 3010. The tool 3040 also has a shoulder stop
3060 toward one
end to prevent the post 3000 from sliding backward as it's being inserted.
Figure 95B shows a
magnetic securing post 3000 slid into position against a shoulder stop 3060 on
a magnetic
insertion tool 3040 and Figure 95C shows the underside of a magnetic securing
post 3000 on a
magnetic insertion tool 3040 exposing the South Pole 3030 of its locking
magnet 3020.
Figure 96 shows a cropped view of the cross section of an ¨A¨ and ¨B¨ junction
2510
and the insertion tool 3040 with a magnetic securing post 3000 loaded on it,
ready to be inserted.
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Figure 97 shows a similar view to Figure 96, with the introduction of a small
steel
retaining disk 3070 used to hold the magnet in a steel recess 3080 in the post
slot 510. Figure 98
shows the small steel retaining disk 3070 bonded in the steel recess 3080.
Figure 99 shows a
magnetic securing post 3000 locked in position with the South Pole 3030 of the
locking magnet
3020 magnetically secured to the small steel retaining disk 3070.
Figure 100 shows a modular array 2500 locked with a sample structural backing
(here, a
capacitor wall section 2900).
Figure 101 shows a complete (male) capacitor wall section 2900. The capacitor
rack
3200 shown here is explained in Figure 111.
Lithium-ion batteries charge and discharge electricity through a chemical
reaction.
Capacitors store energy via a static charge within a cell. In this non-
limiting embodiment, the
solar energy collected through the pyramid wall system will be stored in
pyramid shaped
capacitor cells 3100 as shown in detail in Figures 102-109. These cells,
called "supercapacitors",
"ultra-capacitors" or "double layer capacitors", are particularly suited to
compliment battery
technology.
These "supercapacitors" have a number of advantages over batteries including:
a twenty
year life span, lighter weight, 98% efficiency, ability to charge/discharge
over a million cycles,
use of non-toxic materials, won't overheat and ability to operate down to -40
C. However,
conventional supercapacitors can only discharge over a range of seconds to
minutes, which
makes them ill-suited for applications where continuous power is needed. They
cost
approximately twenty times more than comparable lithium ion batteries and have
about 1/3 of
the storage capacity. This capacity is directly related to the surface area of
electrodes in the
capacitor. Accordingly, the electrodes are printed in a variety of dense
patterns with
superconductive material.
In one non-limiting embodiment, the capacitor cells 3100 will have electrodes
formed
into layers of a honeycomb lattice and with a base material of conductive
thermoplastic. It is
then coated with graphene, or equivalent nano-particles, to increase surface
area and a
superconductive gel electrolyte is introduced between the layers. This
increased surface area
increases the storage capacity. The gel electrolyte also increases energy
density, extending
discharge time to match that of batteries.
Conventional batteries have a high energy density allowing them to be used for
applications where power is needed for several hours. But they can also take
several hours to
charge. Supercapacitors have a high power density, meaning they can charge and
discharge in a
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fraction of seconds to minutes. This is useful when power is needed quicldy
(microseconds to
minutes) to avoid data crashes during a blackout and/or in large amounts
(regenerative braking
for trains). Batteries are often used for applications that require long term
discharge, but degrade
significantly over time (limited to a few thousand charge/discharge cycles),
especially under
heavy load. By shifting load spikes to a supercapacitor, the life of the
battery can be extended. In
another non-limiting embodiment, lithium-ion batteries can be introduced into
the pyramid cells
to alternate with the capacitors.
Figure 102 shows the cathode contact side of a capacitor cell 3100. Four of
these cells
3100 can be put into a capacitor wall section 2900.
Figure 103A shows the anode contact side of the capacitor cell 3100. Shown
are: the
capacitor insulated cover 3110, the two anode conductive posts 3130, one of
the four bulbous
bosses 3165 that protrude from the capacitor cell casing 3160 to lock in a
capacitor rack 3200
(see Figure 110), one of the two cathode conductive posts 3170, the two
capacitor cover handles
3180 and an LED socket 3190. The capacitor handles 3180 may be used to remove
a damaged
cell, whose status can be determined by viewing an LED through a port hole in
one of the
handles 3180 that leads to the LED socket 3190. Figure 103B shows a capacitor
cell 3200
rotated to be sectioned in subsequent views and highlighting the same features
as figure 103A
with the inclusion of one more bulbous boss 3165.
Figure 104A shows an insulated cover 3110 sectioned to reveal a honeycomb
anode
3120, an LED 3105 and a cathode LED channel 3125. In one non-limiting
embodiment this
channel 3125 is made by the insulated cover 3110 overmolding an LED lead with
insulative,
thermoplastic resin. In another no-limiting embodiment, the insulated cover
3110 is 3D printed
with a similar material, the printing paused, a wire inserted and the process
resumed. In another
non-limiting embodiment, the channel 3125 is hollow and coated (or printed)
with graphene or
another conductive nano-particle material.
Figure 104B is a cropped detail of Figure 104A and highlights the LED 3105,
cathode
LED channel 3125 and the cathode channel boss 3145 which protrudes near the
edge of a
honeycomb cathode 3150 and connects to the cathode LED channel 3125. The
honeycomb
cathode 3150 is shown in Figures 107A-107F.
Figure 104C shows an exploded view of a capacitor cell 3100, with the
insulated cover
3110, honeycomb anode 3120 and LED 3105 removed. The capacitor cell casing
3160 and
honeycomb cathode 3150 are in place.
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Figure 104D shows a cropped, detailed area of a section of an insulated cover
3110 and a
honeycomb anode 3120. The sectioned area exposes an LED 3105, cathode LED
channel 3125
and the LED contact cavity 3115 that is formed into the honeycomb anode 3120
to house the
positive lead of the LED 3105.
Figure 104E shows the insulated cover 3110 joined with a honeycomb anode 3120,
with
the anode conductive posts 3130 showing through the capacitor cover holes 3140
(shown in
Figure 105A).
Figure 105A shows the insulated cover 3110 separated from a honeycomb anode
3120
with the anode conductive posts 3130 and capacitor cover holes 3140
highlighted. Figure 105B
to shows
the reverse side of the insulated cover 3110 joined with the honeycomb anode
3120.
These two components 3110, 3120 are secured together, as detailed in Figure
105D-105F.
Figure 105C is a section view of Figure 105B, revealing the LED 3105 and the
cathode LED
channel 3125.
Figure 105D is a section view of Figure 105B, revealing tapered cover bosses
3195 on
the insulated cover 3110. These bosses 3195 secure the anode 3120 and prevent
the anode 3120
from touching a cathode 3150 by press fitting inside of the honeycomb spaces.
Figure 105E is a
cropped detail view of Figure 105D that shows one covered boss 3195 and a
section view of the
cathode LED channel 3125, normal to its axis.
Figure 105F shows the honeycomb anode 3120 separated from the tapered cover
bosses
3195 on the insulated cover 3110. Also shown are the tab slots 3175 in the
cover 3110 that are
used to hold the tabs 3185 (shown in Figure 107A) on a capacitor cell casing
3160 when they
are bonded together. Figure 105G is similar to Figure 105F and shows the
addition of an LED
3105 in the exploded view. Figure 106 shows a close-up view of the indicator
LED 3105.
Figure 107A shows the capacitor cell casing 3160 and the honeycomb cathode
3150
together, as well as casing tabs 3185 to be inserted in tab slots 3175 on the
insulated cover 3110.
The pyramid shape of the casing 3160 has the same 3D "footprint" as a solar
panel module 2000
allowing a consistent modular design between these two types of wall sections.
Figure 107B shows the capacitor cell casing 3160 and the honeycomb cathode
3150
separated, with one (of two) cathode conductive posts 3170 visible, as well as
both casing holes
3135 for those posts 3170 and two bulbous bosses 3165. These bosses 3165 have
the same shape
as the conductive tip 1810 on the solar panels 1800; the bosses 3165 provide a
locking feature to
secure the capacitor rack 3200 and carry no current. Figure 107C shows a
cropped detail of a
cathode conductive post 3170.
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Figure 107D shows an assembled capacitor cell 3100 with a sectioned insulated
cover
3110. Highlighted are an anode 3120, the outside edge of a cathode 3150, a
cell casing 3160 a
cathode LED channel 3125, an LED 3105 and a cathode channel boss 3145 to
connect to the
end of the channel 3125.
Figure 107E shows a cropped detail of Figure 107D highlighting the cathode LED
channel 3125 and a cathode channel boss 3145. Figure 107F is similar to Figure
107E with the
insulated cover 3110 raised slightly to show a cathode channel boss 3145.
Figure 108A shows a cropped detail of the top of the capacitor cell 3100 with
the
insulated cover 3110 sectioned across a tab slot 3175 and raised slightly
above a casing tab 3185
to to show its orientation before it is bonded in place. Figure 108B shows
a view similar to Figure
108A with the insulated cover 3110 bonded in place with the tab slot 3175 and
casing tab 3185
in relative position.
Figure 109 shows an exploded view of the components in the capacitor cell 3100
including: the capacitor cell casing 3160, honeycomb cathode 3150, honeycomb
anode 3120,
indicator LED 3105 and capacitor insulated cover 3110.
Figure 110 shows a capacitor rack 3200 removed from a complete (male)
capacitor wall
section 2900.
Figure 111 shows the capacitor rack 3200 in isolation. The capacitor rack 3200
has a
similar construction to the connection rack 2100 except that there are four
(4) bosses, instead of
eight (8), which serve to provide a detent snap fit against bulbous bosses
3250 in the capacitor
cell casing 3160. Figure 112 shows a capacitor rack circuit 3205 with input
lead 3210 and output
lead 3220 to the frame. The capacitor rack circuit 3205 is embodied within the
capacitor rack
3200. Figure 113 shows a circuit contact 3230 to the cathode.
Figure 114 shows a hatch on the tip of a cathode connection post 3170 as a
circuit
contact 3230 is in position. Figure 115 shows a detail of cathode connection
post 3170 and a
cutaway of the capacitor rack 3200 showing the bulbous boss 3165 in the
capacitor cell casing
3160. When the capacitor rack 3200 is in place, the cathode connection post
3170 aligns and
makes contact with the circuit contact 3230.
Electrical conduits within the U-shaped, three (3) sided base 3410 or its top
cover 4400
can connect a solar panel wall 3300 with a capacitor wall 3500. These conduits
can have bypass
and blocking diodes to prevent a back-flow of electrical current from the
capacitors 3100 to the
solar panels 1800. In one non-limiting embodiment, detent/snap fit connection
methods (similar
to those seen in Figures 61-63) provide electrical connection between wall
sections through the
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base 3410 and/or cover 4400. They can be connected in parallel to allow
continuous electricity
in case a section of wall is damaged. In a further non-limiting embodiment,
plug outlets can be
provided in order to draw power from sub-sections of the panels. In another
non-limiting
embodiment, a single outlet is used per wall.
Figure 116 shows an example of a solar panel wall 3300 in a pyramid wall frame
3400.
In addition to V shaped bosses 520 and grooves 530 that hold the sections
together laterally,
dowel pins can be put through these V joints normal to the connection rack
side to prevent
collapse when a force is applied normal to the face of the wall 3300. In the
configuration shown
here, there is one full modular array 2500, four male solar panel sections
2300, one half female
ft)
sections (right side) 3700, one half female section 3800 (left side), one half
female section (top)
3900 and one half female section (bottom) 4000.
Figure 117 shows the backside of a pyramid wall frame 3400. Here, a capacitor
wall
3500 compliments the solar panel side with capacitor shields 4300 covering the
face of every
panel and half section.
Figure 118 shows the U-shaped, three (3) sided base 3410 of the pyramid wall
frame
3400. Figure 119 shows pyramid frame corners 3420 added to the frame as a
cosmetic shield to
missing quarter panels.
Figure 120 shows two top half female sections 3900 inserted at the bottom of
the frame
3400, Figure 121 shows one male side ¨A¨ wall section 2900 added in the center
and two
female side ¨B¨ wall sections 2400 on either side of it. Figure 122 shows one
half female
sections (right side) 3700 and one half female section 3800 (left side) added
to either side.
Figure 123 shows the remainder of sections added: two female side ¨B¨ wall
sections 2400,
three male side ¨A¨ wall sections 2900 and two half female sections (bottom)
4000.
Figure 124 shows the capacitor wall 4100 in place. Figure 125 shows the frame
cover
4200 ready to be put in place.
Figure 126A shows a capacitor shield 4300 ready to position in place. Figure
126B
shows maintenance handles 4310 with a transparent window 4320 to see power
outage signals
on the indicator LEDs 3105. Figure 127 shows the capacitor shields 4300 in
place with one
removed for clarity.
Figure 128 shows the opposite side of the pyramid wall frame 3400, exposing
the
connector side of the capacitor wall 4100. Figure 129 shows a frame cover 4200
added to the
bottom.
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Figure 130 shows the solar panel wall 3300 to be added to the assembly 4100.
Figure
131 shows pyramid frame corners 3420 to be added to the frame. Figure 132
shows the top
cover 4400 to be added in order to complete the top and seal the pyramid wall
frame 3400.
Various embodiments of the Pyramid Wall System use an array of pyramid shaped
cavities which contain elements to collect and store solar energy. The base of
these pyramids
may be regular or irregular polygons and the number of sides are unrestricted.
Reflectivity
among the panels maintains the same power output as if they were laid flat.
This allows for
installations where the surface area is restricted. The angle of each side
with respect to the base
of the pyramid can range between 5 and 85 in the Pyramid Wall System.
The combined area of the sides of any pyramid with a polygon base is always
greater
than the area of the base. As the angle between the sides and the base becomes
greater or
steeper, so does the difference in area. However, there are tradeoffs between
panels arranged to
form shallow and steep angled pyramids. The steeper the angle, the lesser the
footprint and the
greater the internal reflectivity, but the more sensitive the system is to
tracking (needing
overhead light for maximum efficiency). The shallower the angle, the greater
the footprint and
the lesser the internal reflectivity, but the less sensitive the system is to
tracking.
Figure 133 has images of a moderately angled pyramid with a rhombus or diamond
shaped base. The first is a section view showing the angle of its sides. Next
is area of its base or
foot print. At the bottom is the area of its sides.
The Pyramid Wall System has balanced this trade off with a rhombus (diamond)
shaped
base and sides to form compound angles as shown in Figure 133. It is 33.6
from the long
diagonal to horizontal. The increased surface of sides 4520 to base 4500 is
62.2%, allowing a
38% reduction in footprint 4510, while maintaining the same power output. This
reduced
footprint 4510 can accommodate irregular sides, angles or obstructions in wall
or roof designs
such as windows, chimneys, vents or outlets. Conversely, this configuration of
the Pyramid Wall
System will allow a 62% increase in power over a comparable flat panel system
covering the
same footprint 4510.
The Pyramid Wall System is not limited to the geometry described in Figure
133.
Alternate configurations allow shallower angles; as low as 5 from horizontal
4550, for setups
where there are height restrictions or other requirements of geometry as shown
in Figure 134.
The surface area increases over footprint 4540 in this configuration 4530 is
marginal (1.4%), but
does not use tracking. Also, it is more adaptable to conventional panel
setups.
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Other configurations allow steeper angles; as high as 85 from horizontal
4580, for
setups where there is a restriction in mounting surface area. The surface area
increase over
footprint 4570 in this configuration 4560 is 2,100% as shown in Figure 135.
Arrays of these
sharp pyramid configurations can be applied where footprint area is highly
restrictive, vertical
space is not an issue and a tightly controlled tracking system is in place.
In other, non-limiting configurations of this system a steeper side angle with
a square
base may be used, giving a surface area increase of 149%. Such configurations
have the same
triangular shaped panels 4520 as in Figure 133, with the short sides forming a
square shaped
perimeter at the open footprint of the pyramid. Such as system would benefit
more from
Hi tracking.
In further, non-limiting embodiments, the pyramid sides may be uneven.
Sections that
have restricted access to sunlight may have sides of extended or retracted
length to best capture
incident light. Arrays may combine inverted pyramids of equal and unequal
size.
Figure 136 shows two examples. The first embodiment 4585 is symmetrical along
the X-
axis, but sides 4586 and 4587 have unequal surface areas. The other embodiment
4590 is
symmetrical along the Y-axis, but sides 4591 and 4592 have unequal surface
areas.
Both embodiments 4585, 4590 have the same area and geometry of footprint 4510
(also
shown in Figure 133) and a comparable increase in surface area among their
sides 4586, 4587,
4591 and 4592. Embodiment 4585 has an increase of 59.8% and embodiment 4590
has an
increase of 60.6%. Asymmetry is not restricted to a single axis; sides may be
unequal along both
X and Y axis. The footprint geometry is not limited to a set number of sides,
nor are side lengths
limited to being equal.
Inverted pyramids have their sides spaced away from building surfaces, as
shown in
Figure 137, allowing natural air flow 4595 to cool cells, increasing
efficiency as heat is reduced.
Internal reflectivity 4596 is shown as a schematic representation in Figure
137. This
reflectivity among panels allows them to be arranged in a smaller footprint
while maintaining
the same, or comparable power output. A sphere is added to the top inverted
pyramid cavity to
demonstrate the orientation of the geometry; that it is indeed a set of 4
inverted pyramids.
In Northern climates, panels can have solar cells on both sides, taking
advantage of the
reflectivity of snow. Single sided panels can also show an increase in power.
In coastal climates
single and dual sided panels can take advantage of the reflectivity of water.
The Pyramid Wall
System is not limited by the number of inverted pyramid "cells" or "modules".
It can be as small
as one or extended indefinitely. The Pyramid Wall cells or modules are
scalable.
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While conventional solar panels can be used in the Pyramid Wall System, it is
not
limited to existing photovoltaic technology or materials. Panels may be
introduced into the
inverted pyramid spaces in a variety of ways. In some non-limiting
embodiments:
= Solar Panels may be assembled flat and hinged, creating a cross shaped
pattern
bonded or snap fit to the inside faces of pyramids.
= Solar panels may be flexible, formed as a cross shaped flat pattern and
"4D"
folded into a pyramid shape to be bonded or fit to the inside faces of
pyramids.
= Flexible solar panels may be in a cross shaped flat pattern and "4D"
folded
into a pyramid shape.
to =
Solar panels may be single sided or bifacial and made with conventional
manufacturing methods or through additive manufacturing, also known as 3D
printing. They may be made in part or in full with specific 3D printing
methods such as Fused Filament Fabrication (FFF), Fused Deposition
Modeling (FDM), Stereolithography (SLA), Selective Laser Sintering (SLS)
and Direct Metal Laser Sintering (DMLS). In one non-limiting embodiment,
this may include a process which cures SLA resin with oxygen and UV light
increases print speed up 25X to 100X. This ultrafast additive method is geared
toward full production. They may be transparent in the visible spectrum and
made of inorganic materials such as perovskite or organic salts. They may use
graphene or equivalent superconductive material to create transparent
nanowires to form transparent contacts throughout and along the edges. They
may use graphene or equivalent superconductive material to coat conventional
electrical contacts, which may be opaque. In the latter case, the density of
the
contact pattern throughout the panel and coverage along the edges may be
affected. Panel contacts may be arranged in a dense geometric pattern such as
(but not limited to) a honeycomb shape, to increase contact surface area and
efficiency. The panels and its contacts may be made through chemical etching,
laser etching, with other conventional manufacturing methods, 3D printed
with conductive material or with any combination thereof. Solar panels may
be secured in a mounting post which will allow a conductive path through a
central location. Mounting post wiring layers may contain embedded/over-
molded wires. They may house molded, machined or 3D printed channels or
conduits with inserted leads to create the wiring layers. The layers may have
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3D printed conductive leads. The channels or conduits in the mounting posts
may be sprayed or electroplated with conductive material or superconductive
material such as graphene or equivalent. They may be coated with conductive
or superconductive gel.
= Wiring layers may be produced with any combination described herein and
stacked for multiple sets of panels. The mounting post body may be extended
with slots added to allow for the stacking of multiple panel arrays. Panels
transparent to visible light (or specific wavelengths) may be stacked within
the
pyramid space, each layer positioned to absorb a specified range of
wavelengths. Panel layers may be flat and parallel to each other or flat and
independently oriented/angled/positioned to each other. Panel layers may be
curved to form any geometric or non-geometric shape. They may be
concentrically nested or independently oriented/angled/positioned to each
other. They may be staggered and offset, like the petals of a rose. If panels
have opaque edge contacts, they may only extend part way along the sides and
avoid the top so as not to obscure panels underneath. Otherwise, transparent
contacts may be used along the perimeter of the panel.
= Panels may have a transparent outer surface that functions as any type of
conventional simple lens, lenticular lens or Fresnel lens. These lenses may be
of a variety of shapes and have a variety of purposes including focusing,
defocusing and redirecting light. Figure 69 shows a wave shaped solar panel
1800. Figure 69 also highlights a sample area of this panel 1840. In one non-
limiting embodiment, Figure 70 details this sampled area and shows a solar
cell cover with gradient wave patterned, refraction steps.
= Panel surfaces may have specific areas coated with anti-reflective and/or
polarizing compounds.
= The inside faces of the pyramids may be coated (or lined) with
electroluminescent paint, electroluminescent tape, or light-emitting diodes
(LED)s. LEDs may be individual components in an array, in a ribbon or in a
sheet. This allows for nighttime use if transparent/semi-transparent cells are
used. These lighted faces enable self-sustaining light by drawing power
through an inverter connected to electrical storage such as supercapacitors
and/or batteries in the Pyramid Wall modules.
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In one non-limiting embodiment Figure 138, a hinged, cross shaped panel
assembly
4600 is shown in an exploded view. Four triangular shaped panels 4610 are laid
flat. At the
smallest inside edge of each these panels is a hinge 4620 bonded in place. At
the bottom center
of the assembly is a mounting post hub 4630 which has the bottom portion of a
cavity to hold
the hinges in position and allow a mounting screw 4640 to secure the panel
assembly into the
inverted pyramid space. A mounting post body 4650 has the top portion of a
cavity to secure the
hinges in position, allowing it to rotate with one degree of freedom. It may
be bonded into the
hub 4630.
Figure 139 highlights slots 4660 in the mounting post body 4650. Additional
panels
i() 4570 are positioned to slide into place. In Figure 140, a mounting post
body 4650 is shown
surrounded with exploded components. This body 4650 has several purposes: it
connects all of
the panels 4610, 4670 to a central location, houses the internal wiring and
provides a countersink
to fasten a panel assembly 4600 into an inverted pyramid cavity.
Below the mounting post body 4650 is the mounting hub 4530, which will be
positioned
in the inverted pyramid cavity. External leads 4680 protrude from body 4650
just above the hub
4530. A mounting screw 4640 is just above the body 4650 and a protective
access cap 4655 with
snap fits 4656 is just over the screw. In one non-limiting embodiment, the
protective access cap
4655 may have a generally pyramid shape and a reflective coating to reflect
light back to the
solar panels 4610, 4670,
Figure 141 shows a section view of a mounting post, partly exploded components
and
detail of features. This includes the mounting hub 4630, the mounting post
body 4650 (its
internal wiring hidden for clarity), the protective access cap 4655, the snap
fits 4656 in the cap
4655, the snap fit sockets 4657 in the mounting post body 4650 and the slots
4660 for the second
array of panels 4670. The mounting post body 4650 may be extended with
additional slots 4660
added to allow for the stacking of multiple panel arrays 4670.
In this non-limiting embodiment, Figure 142 shows a transparent panel 4610
with a
section view of its hinge 4620 and Figure 143 highlights a section view of the
hinge 4620. The
negative contact on a lead 4621 can connect to a socket in a mounting post
body 4650, a positive
contact on a lead 4622 can go into the body of the hinge 4620 and a positive
lead contact 4623
connects to a panel lead.
Figure 144 shows a detail of a cropped cross section, where a panel 4610 and
its hinge
4620 are connected and positioned horizontally; its positive lead 4622 is
inside a cavity in a
mounting post body 4650. A second panel 4670 is also in position in the cavity
in the mounting
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post body 4650, while two leads 4680 from the internal wiring are exposed. A
mounting hub
4630 is ready to be put in place.
Figure 145 shows a detail of a cropped cross section where panel 4610 and
hinge 4620
are folded into position. Positive contact on lead 4622 and second panel 4670
are shown for
reference and mounting hub 4630 is now in position.
Figure 146 shows the hinges 4620 in the flat position. It highlights the
hinges' four
negative contacts on leads 4621 that go into a mounting post body 4650 as well
the four positive
contacts 4622. The first layer of wiring 4681 and the connecting leads to the
second layer of
wiring 4682 in the cross panel mounting post is shown. These wiring layers may
be
w embedded/over-molded wires in the mounting post or have 3D printed
conductive leads. Or they
may be have molded, machined or 3D printed channels in the mounting post base
with inserted
leads, coated with sprayed or electroplated conductive material, coated with
conductive or
superconductive gel or they may have any combination thereof
Figure 147 introduces the second layer of wiring 4682 to connect to the second
layer of
panels and electrical leads 4680. These wiring layers may be stacked for
multiple sets of panels.
Figure 148 shows hinges in the folded position exposing the negative and
positive leads 4680
which will connect through the mounting hub.
Figure 149 shows three back panels 4610 in the flat position, a fourth back
panel 4611
folded up exposing its backside which in one non-limiting embodiment, may be
coated with
electroluminescent paint, electroluminescent tape or LEDs for night time use.
These panels are
transparent or semi-transparent to visible light. The backside also has snap
fits 4612 to help
secure the panels 4610, 4611 in the inverted pyramid housing, which in one non-
limiting
embodiment, has its inside faces coated with electroluminescent paint,
electroluminescent tape
or LEDs. Also shown is the second layer of panels 4670.
Figure 150 shows a transparent panel 4610 and its lattice of contacts. In one
non-limiting
embodiment, these contacts are honeycomb shaped, to increase contact surface
area and
efficiency. The panels 4610 and its contacts may be made with conventional
manufacturing
methods, 3D printed with conductive material or a combination of the two.
Figure 151 highlights a cropped detail of a panel 4610, highlighting its
honeycomb
.. lattice 4613 of contacts. Its positive edge contact 4614 and positive hinge
socket 4617 are
shown. Also shown is its negative edge contact 4615 and negative hinge socket
4616.
Figure 152 shows a further close-up of the connections and contacts 4614,
4615. The
honeycomb lattice 4613 connects to the edge contacts on both sides. Detail is
shown of the
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following: a section of the positive edge contact 4614, the geometry of the
housing for positive
hinge socket 4617, negative edge contact 4614 and a section view of negative
hinge socket
4616.
Figure 153 shows a completed, folded cross panel assembly 4600 and notes the
outside
layers where electroluminescent paint electrolurninescent tape or LEDs 4611
will be applied to
the transparent or semitransparent panels.
Composite wall sections can be manufactured using a variety of processes.
Pyramid
Wall sections may be vacuum formed over molds using composite sheets. These
sections can
range from small modular "A" and "B" mating sections to full wall panels (as
described above).
it)
Pyramid Wall sections may also be made through additive manufacturing, also
known as
3D printing. They may be made in part or in full with specific 3D printing
methods such as
Fused Filament Fabrication (FFF), Fused Deposition Modeling (FDM),
Stereolithography
(SLA), Selective Laser Sintering (SLS) and Direct Metal Laser Sintering
(DMLS). In one non-
limiting embodiment, a process which cures SLA resin with oxygen and UV light
increases print
speed up 25X to 100X. This ultrafast additive method is geared toward full
production.
Pyramid Wall sections may be FFF/FDM 3D printed in layers using chopped carbon
fiber with a thermoplastic base or continuous strands of fiber with
thermoplastic base. The
chopped carbon fiber and thermoplastic base may be in the form of pellets,
filament or
combination thereof.
The Pyramid Wall System can form an array of hollow, inverted pyramids.
Conventional
FFF or FDM 3D printing technology uses an extruder head that follows a
complete horizontal
path before moving to the next level. While advancements in machine speed and
material
throughput can make these parts faster, extruders on conventional printers are
limited to three
degrees of freedom.
Incorporating robotic arms into the 3D printing process lets extruders move
with six
degrees of freedom, allowing non-orthogonal movement to match the geometry of
the sections.
This speeds up the process for manufacturing. The robotic arms may travel on a
conventional
linear rail or linear gantry system or move autonomously. Robotic arms may
travel in a
curvilinear motion on a simple curved track, a compound curve track or a three
dimensionally
curved path. Robotic arms may work as individual units or as multiple arms
moving in unison or
independently.
The Pyramid Wall System may be FFF/FDM 3D printed in part or in full by
extruders
on robotic arms, incorporating conventional FFF/FDM or other production
methods.
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Combinations of conventional FFF 3D printing and robotic 3D printing can be
used when using
multiple materials and extruder diameters. These options allow large volume
prints made with
large diameter extruders and to have detailed features made with smaller
diameter heads.
In one non-limiting embodiment, Figure 154 shows a flexible screw conveyor
4700 for
handling pelletized plastic for use in robotic 3D printing. It labels the
following: a control panel
4710 for the system, a stand 4720, conduits 4730 and an electric motor 4740. A
feeder 4750 is
shown (to be connected via hose to one of the 3D printer's extruders). Also
shown is a flexible
screw enclosure 4760 and a cutaway view of the flexible screw 4770. This screw
4770 draws
pellets up to the feeder 4750. Pelletized plastic 4780 is shown feeding into
the flexible screw
1()
enclosure 4760 which is attached to the main hopper 4790. This hopper 4790
stores material to
print and has its hinged hopper door 4785 removed for clarity.
Figure 155 shows a partial setup of a robotic 3D printing system 4800.
Production
systems may use multiple robotic arms for printing, as well as extruders on
gantries as in
conventional FFF or FDM printing. A gantry or linear rail 4810 allows
controlled movement of
a linear guide 4820. A robotic arm 4830 allows it to repeatedly position an
extruder head
(detailed in Figure 156) with multiple degrees of freedom. A hose 4840 gravity
feeds pellets to
the extruder at the end of the robotic arm. The hopper door 4785, which was
removed in Figure
154, is shown. A completed wall section 4850, such as one made using the
robotic 3D printing
system 4800, is also shown.
Figure 156 shows detail of a cropped section of an exploded view of a robotic
arm 4830
and extruder. The end of the arm 4830, hopper feeding tube 4840, stepper motor
and tube
coupler 4860, heating cartridge 4870, thermistor (heat sensor) 4880 and an
extruder hot end and
nozzle 4890. Filament may be used instead of or in combination with the hopper
fed, pelletized
plastic.
In other, non-limiting embodiments, molds or forms for composite wrapping may
be 3D
printed using additive manufacturing processes such as FFF or FDM. They may
also be made
through SLA, SLS or DMLS. As described above, the pyramid mold core 100 can be
made
through 3D printing processes such as Fused Filament Fabrication (FFF) or
Fused Deposition
Modeling (FDM). Molds may be made with a CNC milling machine or router. Molds
may also
be made by pouring a variety of material (including but not limited to plastic
and concrete)
between back-to-back wall sections.
Pyramid Wall sections may be made from Vacuum formed thermoplastic sheets.
Pyramid Wall sections may also be injection molded, rotomolded, cast, and/or
extruded.
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Wall sections may be made flat through any of the above processes (e.g.,
additive
manufacturing or molding) to be stacked for storage and transportation. The
sections can then be
deployed into shape manually by incorporating a living hinge. Or they may take
final form over
a mold shape. They may also take form in a "4D" process by using an outside
stimulus such as
heat, electricity or a chemical reaction.
Substitute materials for composite mold wrapping include: fiberglass and
Kevlar.
Substitute material for FFF/FDM 3D printing includes fiberglass and Kevlar
(strands or
chopped), thermoplastics (by themselves), concrete, cement, wood pulp,
composite wood with
binder, and recyclables. These materials can be fed as pellets, filaments or
combinations thereof
and extruded through the 3D printer nozzle.
Substitute materials for various mold process include: wood pulp/composite
wood,
recyclable material (including plastic) and composite embedded thermoplastics,
cement or
concrete.
Walls may be milled or routed out of plastic or wood; made out of sheet metal;
or
stamped into shape.
Any of the components in the Pyramid Wall System may be completely
manufactured
with any of the processes described herein or in a combination of such
processes.
In one non-limiting embodiment, shown in Figure 157, a vacuum/thermoforming
setup
4900 is shown. A form 4910 shaped as the inside faces of the inverted pyramids
in a wall panel
section has a network of vacuum tubing 4920 attached to its backside. Figure
158 shows the
setup 4900 including the top of the form 4910, a network of vacuum tubing
4920, a section of
the tubing and a section of the form 4910 showing where the vents connect to
the vacuum path.
Figure 159 shows a detail of this section view with the form 4910, vacuum
tubing 4920,
sectioned vent hole 4930 and a section of vacuum tubing aligned with vent
holes in the form
4910,
Figure 160 shows the thermoforming setup 4900 with a heated thermoplastic
sheet 4945
above it. Figure 161 shows a pyramid array 4950 formed from a thermoplastic
sheet and
removed from the form 4900.
Figure 162 shows an exploded view of a thermoformed pyramid wall 4990, and its
components. At the bottom is the pyramid array 4950. Above that is the array's
support frame
core 4960 (dummy or with bird-bone and conductive/insulative layers), the
support frame's top
with sockets 4970 and mounting plugs 4980.
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Figure 163 shows the back side of a completed wall section 4990. Figure 164
shows the
front side of that wall section and the inside face of the thermoformed
pyramid array 4950.
In one non-limiting embodiment, shown in Figure 165, a conventional injection
mold
5000 (without side action) is used to create a complete wall section. A
section view of the
molten plastic channels is shown starting with the sprue 5010 and the runners
5020 which
extend the entire length of the mold. The runners are then connected to gates
5030 which
terminate at points in the mold core 5040 (in a similar orientation to the
vents 4930 in the
thermoforming images such as in Figure 159).
Plastic can then be allowed to flow from the gates into mold cavity 5050 while
top
.. support plate 5060 and bottom support plate 5070 keep the mold 5000 closed.
In Figure 166, a completed wall section 5100 is shown ejected from the mold,
with the
mold core 5040, top support plate 5060, mold cavity 5050 and bottom support
plate 5070 shown
open. Figure 167 shows the back side of a single part wall section 5100 with
completely molded
features. In another embodiment, any of the features on the molded part may be
removed, with
the entire wall section assembled from multiple parts.
In standalone sections, separate wall sections can be connected back to back
with
fasteners. The axis of the posts and sockets may be aligned as posts are fit
into sockets to be
secured. Alternatively, sockets may have semi-circular cutouts so that posts
may slide in. These
standalone sections have space which can be filled with closed cell foam or
pellets of a variety
of material (including recycled plastic or paper) or cement. This filler
material may be used for
thermal insulation, sound absorption or both. A lattice can be inserted
between sections and
reinforced with material such as closed cell foam. The lattice may be made
through conventional
manufacturing methods including additive manufacturing, also known as 3D
printing. It may be
made in part or in full with specific 3D printing methods such as Fused
Filament Fabrication
(FFF), Fused Deposition Modeling (FDM), Stereolithography (SLA), Selective
Laser Sintering
(SLS) and Direct Metal Laser Sintering (DMLS). In one non-limiting embodiment,
a process
which cures SLA resin with oxygen and UV light increases print speed up 25X to
100X. This
ultrafast additive method is geared toward full production.
The lattice may also be printed in the inside face of one of the standalone
wall sections,
with the sections joined later.
Figure 168 shows two wall sections back to back and separated, in position to
form a
standalone pyramid wall sandwich 5200. In one non-limiting embodiment, Figure
169 shows
cropped section of a wall sandwich 5200 showing back to back sections in
position and pyramid
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arrays 4950. Detail of that section includes a socket 4970 on one side with a
drainage port 4975.
A plug 4980 is shown opposite the socket with a drainage port 4985 in line
with the port on the
socket. The drainage port can be used for water, moisture and as a vent for
heat.
Figure 170 shows a breakaway view of the standalone pyramid wall sandwich
5200. In
this non-limiting embodiment, closed cell foam 5210 is shown partially filling
the cavity
between wall sections.
As shown in Figure 64, solar panel connection racks 2100 connect each of the
four sets
of four panels into one socket in the frame. (For example, in Figure 101,
capacitor/battery
connection racks 3200 connect each battery/capacitor in the same fashion).
An alternate/supplemental connection method for a single sided Pyramid Wall
section is
to have their center posts form an electrical hub which connects the solar
panel leads. This hub
then connects into a cavity in a Wall Socket which has been mounted onto a
wall or support
surface. A fastener protrudes from the hub which is secured into an embedded,
threaded insert in
the Wall Socket cavity. The cavity has electrical contacts which then draw
power from the hub
and transfer it to a wiring harness or electrical conduits in an
Aligning/Mounting
Template/Fixture. Cutout sections in the Aligning/Mounting Template/Fixture
can have the
same profile as a Wall Socket. Notches in the cutout sections provide relief
for contact nipples in
the Wall Sockets.
The Aligning/Mounting Template/Fixture may also be used as a temporary
mounting
template to align the wall sockets before they're fastened or bonded into a
wall. The template
would have no electrical conduits or embedded wiring. It could be for Wall
Socket alignment
and then be removed.
As a permanent mounting fixture, the Aligning/Mounting Template/Fixture may or
may
not include electrical conduits or embedded wiring. It may be completely
supported by sockets
after they are fastened or bonded into a wall. The Aligning/Mounting
Template/Fixture may be
fastened or bonded independently to provide additional support for the Pyramid
Wall Section.
The Wall Sockets and Aligning/Mounting Template/Fixture may be machined,
routed,
laser cut, water cut or molded through various methods including injection
molding. They may
be formed through additive manufacturing, also known as 3D printing. They may
be made in
part or in full with specific 3D printing methods such as Fused Filament
Fabrication (FFF),
Fused Deposition Modeling (FDM), Stereolithography (SLA), Selective Laser
Sintering (SLS)
and Direct Metal Laser Sintering (DMLS).
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Electrical contacts in the Wall Sockets and conduits in the Aligning/Mounting
Template/Fixture may be over-molded wires, 3D printed with conductive
material, or a path for
insulated wiring. The conduits may be coated with superconductive material
such as Graphene
or equivalent and/or filled with superconductive gel or any combination
thereof.
The Wall Sockets and Aligning/Mounting Template as a permanent fixture may
have
mounting holes to allow fastening to a mounting surface. Alternatively, the
Wall Sockets and
Aligning/Mounting Template may be secured with fasteners (such as screws); a
bonding
compound or a combination thereof
In Figure 171, a single, diamond Pyramid Wall section 4900 is shown above a
Wall
Socket 5300 and an Aligning/Mounting Template/Fixture 5400. In one non-
limiting
embodiment, the Template 5400 can be used to temporarily position Wall Sockets
5300 as
they're secured onto walls, roofs or other surfaces with fasteners or bonding
compounds. In
another non-limiting embodiment, the Template 5400 is permanently secured for
reinforcement
and/or to provide an electrically conductive path between panel sections,
capacitors and/or
batteries.
Figure 172 shows a detail of an exploded view of a Wall Socket 5300 sectioned.
It
shows a Socket body 5310 with nipples for electrical leads 5315. It is
sectioned to show the
counter-bore for a Pyramid Wall post, a drainage area in the counter-bore 5316
and a thru hole
for a brass threaded insert 5320. The drainage area allows moisture to escape
and heat to vent.
The insert 5320 is aligned to accept a screw 4640 and secure the Pyramid Wall
post, which
houses a solar panel assembly.
In one non-limiting embodiment, concreate screws 5330 (for example, Tapcon
screws
used to secure fixtures to concrete) will be used to secure the Wall Socket to
a wall or roof.
Figure 173 introduces the post of a Pyramid Wall section into the Wall Socket
image. A solar
panel lead 4680 from a panel array in the Pyramid Wall section is aligned with
a conduit 5340 in
the Wall Socket.
Figure 174 adds a detailed section of an Aligning/Mounting Template/Fixture.
In this
non-limiting embodiment, its conduit 5410 is exposed and aligned with the Wall
socket conduit
and the solar panel lead. This conduit 5410 may be a path for insulated
wiring, over-molded
wires or 3D printed conductive material. The conduits 5410 may be coated with
superconductive
material such as Graphene or equivalent and/or filled with superconductive gel
or any
combination thereof
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Figure 175 shows a section of a completed Pyramid Wall System 4990 as it
connects
into a Wall-Socket 5310. The Aligning/Mounting Template/Fixture 5400 aligns
each Wall
Socket and can either be removed after being an alignment tool or permanently
fixed with
electrical conduits. Figure 176 shows detail of an exploded view of a Pyramid
Wall 4990, some
Wall Sockets 5300 and an Aligning/Mounting Template/Fixture 5400. Figure 177
Removes the
Pyramid Wall and shows a close-up of the image. Wall Sockets 5300 are in
position to be fit into
the receiving cavities of an Aligning/Mounting Template/Fixture 5400. Mounting
holes 5420
may be used to secure the mounting template onto a surface. The holes may be
left as is or
modified with countersunk holes for fasteners.
In one non-limiting embodiment, the Pyramid Wall System can take advantage of
space
within the pyramid space to position layers of semitransparent or transparent
cells/panels to
absorb specified wavelengths of visible and/or non-visible light. This is
shown in Figure 139 and
highlighted in Figures 142, 150, 151 and 152, where a second layer of
"transparent" cells is
introduced. The first layer of solar panels may be single sided or bifacial
and fastened to the
inside faces of the pyramid housing. They may use graphene or equivalent
superconductive
material to create transparent nanowires or to coat conventional electrical
contacts. Panel
contacts may be arranged in a dense geometric pattern such as (but not limited
to) a honeycomb
shape, to increase contact surface area and efficiency.
Both the first and subsequent panel layers may be transparent in the visible
spectrum and
made of inorganic materials such as perovskite or organic salts. They can be
stacked like petals
of a flower around a post or "stem". The stacking may be flat and form the
sides of offset
pyramids around a stem or the sides may be curved and/or overlap like the
petals of a rose. Panel
layers may be flat and parallel to each other or flat and independently
oriented/angled/positioned
to each other. Panel layers may be curved to form any geometric or non-
geometric shape. They
may be concentrically nested or independently oriented/angled/positioned to
each other. They
may be staggered and offset, like the petals of a rose. Individual panels may
be split into two or
more sections and positioned independently. Panel layers may be coated with
anti-reflective
and/or polarizing compounds.
They may be made with conventional manufacturing methods or through additive
manufacturing, also known as 3D printing. They may be made in part or in full
with specific 3D
printing methods such as Fused Filament Fabrication (FFF), Fused Deposition
Modeling
(FDM), Stereolithography (SLA), Selective Laser Sintering (SLS) and Direct
Metal Laser
Sintering (DMLS). In one non-limiting embodiment, a process which cures SLA
resin with
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oxygen and UV light increases print speed up 25X to 100X. This ultrafast
additive method is
geared toward full production.
The panels and its contacts may be made with conventional manufacturing
methods, 3D
printed with conductive material or a combination of the two. Solar panels may
be secured in a
mounting post which will allow a conductive path through a central location.
The mounting post
may be manufactured with conventional manufacturing methods such as injection
molding or
3D printed in any of the various methods described above or combinations
thereof. In one non-
limiting embodiment, transparent superconductive capacitors can be used
between transparent
cell layers for storage.
NOTE: Some of the components in the images used to describe this stacked panel
'Flower' assembly are identical to those in the Cross Panel assembly. Others
are similar to ones
from Figure 138 to 141. But there are instances where individual parts are now
assemblies. So,
for clarity they have been renumbered.
Figure 178 shows an exploded view of panels 4610 and their hinges 4620 around
a
Flower Post assembly 5600. These panels form a Cross Panel assembly similar to
that shown in
Figures 138-153, with the difference that the Flower Post assembly allows
multiple sets of
panels to be stacked. At the bottom of this exploded view is the Flower Post's
Connection Hub
5610. This hub is used to stabilize and secure the panels in the Pyramid Wall
cavities.
Figure 179 introduces a 2nd layer of panels 4670. Figure 180 shows an exploded
view of
a Flower Post assembly 5600. It includes the post's base or hub 5610, the post
body 5620, a
mounting fastener 5630 and an access cap 5640. In one non-limiting embodiment,
it is used to
mount the solar array into a pyramid wall section and into a wall socket. It
may be coated for
reflectivity and contain electrical paths or conduits which may be over-
molded, inserted or 3D
printed with electrical leads. It may have a different profile from the
diamond shape shown, such
as circular, oval or any regular or irregular polygon, it may taper and may be
scaled differently
to account for space restriction.
Figure 181 shows a section view of the Flower Post 5600. The post's hub 5610
is below
the post body 5620 with a mounting fastener 5630 in place in the body's
countersunk hole. The
access cap 5640 is directly over it.
Figure 182 shows a close-up of features on a cropped section view of the
post's body
5620 and access cap 5640. Panel recesses 5622 along the outside of the post's
body 5620
position the different levels of panels. Snap fit sockets 5621 allow snap fits
5641 on the access
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cap 5640 to secure it in place and protect the fastener. Access cap recesses
5642 allow tool
access for quick release.
Figure 183 shows the 1st level of wiring 5650 to connect to the Cross Panel
hinges 4620.
It follows the same circuit, variety of material and manufacturing processes
as the wiring layers
described for the Cross Panel in Figures 146-148. The exception is the serial
connection 5651 to
connect the multiple levels of panels in the cell.
Figure 184 shows the negative and positive leads 5682 which will connect
through the
mounting hub. The 2nd level of wiring 5683 through the 7th layer of wiring
5688 is marked on
one side only for clarity.
Figure 185 shows a stacking from the 2nd level panels 4670 through the 7th
level panels
4675. They are marked on one side only for clarity.
Figure 186 shows a completed, stacked Flower assembly 5700, with the Cross
Panels
4610 in the flattened position, and the Flower Post's hub 5610 exploded.
Figure 187 shows a completed Flower assembly 5700, folded into a pyramid
shape, its
outside surfaces coated with electroluminescent paint, electroluminescent tape
or light-emitting
diodes (LED)s 4611. Panels may be transparent or semitransparent to different
wavelengths
depending on the requirements of the electroluminescent coating or LEDs.
In one non-limiting embodiment, each panel may form a single, flat layer
around the
mounting post, where their exposed faces are parallel to the footprint of the
pyramid. Each layer
may be curved and concentrically nested around the mounting post. Each layer
may be equally
spaced or spaced differently along the mounting post. Each layer may be angled
independently
from each other or in any combination thereof.
Tabs with electrical contacts may be secured in the mounting post slots; their
exposed
edges to connect the leads on the solar panels. They may be secured with
fasteners, snap fits,
bonding agents or any combination, thereof
Panels may be coated with anti-reflective and/or polarizing compounds.
Figure 188 introduces a 1st layer horizontal panel 5800, who's face is
oriented parallel to
the pyramid's base or footprint. The edges of a clearance hole in the
horizontal panel can be
positioned just above the panel recesses 5622 in the flower post. Connecting
tabs 5805 that fit
into the recesses can be bonded or fastened to the 1st layer horizontal panel.
Subsequent panels
may be assembled first, working toward the top.
Figure 189 shows a cross section of several horizontal panels and their
connecting tabs.
The first to be assembled on top of the cross panels is 6th panel 5850 with
connecting tabs 5855.
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Next is 5th panel 5840 and its connecting tabs, 5845. Then 4th panel 5830 with
connecting tabs
5835. Then 3rd panel 5820 with connecting tabs 5825. Then 2nd panel 5810 with
connecting
tabs 5815. Finally, the top layer panel 5800 and its connecting tab 5805.
Figure 190 shows a completed Horizontal Stacking Flower 5900 with Cross Panels
4610
shown flat and 1st layer horizontal panel 5800 highlighted.
Figure 191 shows an alternate section view of the panels and the increased
surface area
from their configuration. It highlights the post's hub 5610, the post's body
5620, the mounting
fastener 5630 and the access cap 5640.
Figure 192 shows the horizontal stacking flower 5900 folded into a pyramid
shape. Its
outside surfaces 4611 are coated with electroluminescent paint,
electroluminescent tape or
LEDs.
In a further non-limiting embodiment, the slacking flower may be non-
horizontal.
In several non-limiting embodiments, transparent covers may be used for
various
purposes within the Pyramid Wall System. They may be used for protection from
weather, to
provide an aerodynamic surface and/or to aid in the collection or dispersion
of light. The
geometry of the covers may be flat, indented or protruding and be of varying
shapes. They may
cover individual cells, small panel sections or large arrays. They may be
uniform or mixed
depending on the application.
Covers may be made from a number of different materials transparent to various
wavelengths of visible and non-visible light. These include but are not
limited to glass,
transparent polymers, transparent inorganic polymers, transparent epoxy resin,
transparent
ceramics and combinations thereof. These materials may be treated with
transparent silica
coatings, transparent epoxy or transparent nano-coatings for protection.
Covers forming a protective barrier for solar panels may also provide
protection for
structures in windy areas. They may reduce drag when used to shield solar
panels on moving
vehicles. Data from wind tunnel tests and computer analysis such as
computational fluid
dynamics (CFD) will determine the specific geometry of a cover segment, as
well as the
arrangement of these segments over a large array.
As the Pyramid Wall System may be exposed to extreme weather conditions,
moisture
and heat ventilation ports can be introduced in various components in the wall
sections. They
may include side walls, edges corners, posts and mounting sockets on the
Pyramid Wall and
corners and edges on the covers.
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Covers may perform a dual function as solar cells transparent in the visible
spectrum and
made of inorganic materials such as perovskite or organic salts. They may use
graphene or
equivalent superconductive material to create transparent nanowires or to coat
conventional
electrical contacts. Panel contacts may be arranged in a dense geometric
pattern such as (but not
limited to) a honeycomb shape, to increase contact surface area and efficiency
(as described
above).
Covers may function as any type of conventional simple lens, lenticular lens
or Fresnel
lens. These lenses may be of a variety of shapes and have a variety of
purposes including
focusing, defocusing and redirecting light. Figure 69 in the original filing
shows a wave shaped
to solar panel 1800. Figure 69 also highlights a sample area of this panel
1840. In one non-limiting
embodiment, Figure 70 details this sampled area and shows a solar cell cover
with gradient
wave patterned, refraction steps.
Covers may be coated with anti-reflective and/or or polarizing compounds.
Covers may be made as individual units for individual pyramid cells. They may
be made
as small modular sections or complete panels. Modular sections or complete
panels may have
custom shaped areas to secure over individual pyramid cells with break-away
features added for
individual units. In this way, only damaged units need to be replaced.
Covers may be made through conventional methods used for producing clear
plastic
sheets including extrusion, casting, blown film, injection molding and
thermoforming.
.. Breakaway sections may be designed as molded features or added with a
secondary
manufacturing process such as water jet cutting, laser trimming or cutting
blades.
Covers may also be made through additive manufacturing, also known as 3D
printing.
They may be made in part or in full with specific 3D printing methods such as
Fused Filament
Fabrication (FFF), Fused Deposition Modeling (FDM), Stereolithography (SLA),
Selective
.. Laser Sintering (SLS) and Direct Metal Laser Sintering (DMLS). In one non-
limiting
embodiment, a process which cures SLA resin with oxygen and UV light increases
print speed
up 25X to 100X. This ultrafast additive method is geared toward full
production (as described
above).
Breakaway sections in 3D printed parts may be made as a design feature using a
single
material. Breakaway sections may also be formed from the grooves/cavities
created after the
removal of 3D print support material. Alternatively, they may be added as a
secondary
manufacturing process such as water jet cutting, laser trimming or cutting
blades.
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NOTE: This section shows examples of covers on horizontal petal setups, with
and
without posts. But they can be used in any of the solar panel variations, as
well as combinations
of capacitors and batteries.
Figure 193 shows a section view of a spherical, concave cover 6010 and
horizontal
stacking flowers 5900. In this non-limiting embodiment, the access cap 5645 is
truncated for
clearance and the cover 6010 fits onto a 4-cell cavity in a wall section 4990.
A center screw (not
shown) may be used to secure the cover along with snap fit features in the
corners.
Figures 194 and 195 show variations of the cover in several non-limiting
embodiments
as examples for a single cell. In Figure 194 a flat cover 6000, a spherically
concave cover 6010,
an oval concave cover 6020 and a teardrop concave cover 6030 are shown. In
Figure 195, a
spherically concave cover with a lens 6040, a spherically convex cover 6050,
an oval convex
cover 6060 and a teardrop convex cover 6070 are shown.
The lens feature is not limited to the spherically concave variation, nor to
any of the
variations in these figures. The lens shape may be any variation of
conventional simple lens or
Fresnel lens. The material for any of the covers may be an optically clear
compound, transparent
solar cells, transparent capacitors or any combination thereof
In one non-limiting embodiment, an alternate version of the horizontal
stacking flower
removes the mounting post for stacking. This allows for a simpler construction
of panels and
more exposed surface area to light. Panel layers may be flat and parallel to
each other or flat and
independently oriented/angled/positioned to each other. Panel layers may be
curved to form any
geometric or non-geometric shape. They may be concentrically nested or
independently
oriented/angled/positioned to each other.
Panel layers may be coated with anti-reflective and/or or polarizing
compounds.
Comers of the panels may provide electrical contact through leads along the
inside edges
of the pyramid cell or the edges between the sides of folded cross panels. A
simplified version of
a truncated mounting post would draw current from the inside edge leads into a
central location
(not shown).
Figure 196 shows an alternate version of the horizontal stacking flower 6100.
The non-
post, stacking flower 6100 is shown with one cross panel 4610 and hinge 4620
removed to show
various features. As in the cross panel, flower and horizontal stacking flower
versions, the
backside of the cross panels 4610 may be coated with electroluminescent paint,
electrolurninescent tape or LEDs.
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In this non-limiting embodiment, six nested panels: 6110, 6120, 6130, 6140,
6150 and
6160 are shown press fit into the cross panel sides. Electrical contacts may
be at the outer
corners of the horizontal panels with the edges of the cross panels 4610
providing a serial
connection. The cross panels may have groove features on the inside face to
hold the horizontal
panels when folded in place or they may be bonded (or a combination of the
two). The panels
may be flat or curved and may be positioned in various orientations within the
pyramid cavity,
not necessarily parallel to the footprint/base of the pyramid. Above the
pyramid cavity is a
spherically concave cover for reference.
Figure 197 shows an exploded view of a truncated locking hub 6200. The hub
base 6210
is similar to the hubs in the cross panel and other flower designs. The hub
body 6220 has the
same function as the cross panel and flower design posts. It provides a wiring
path as in the other
designs and support for the hinge contacts. But it is a much lower profile as
it isn't needed to
support the flower petals. A mounting fastener 6230 is shown above the hub
body, which has a
countersunk through hole to position it. Electric leads 6250 from the wiring
path are shown.
Figure 198 shows a section view of the truncated locking hub 6200. The hub
base 6210
nests the hub body 6220 and the mounting fastener is shown through both. The
internal wiring
has been removed for clarity.
Figure 199 shows the hub base and body removed and highlights the internal
wiring of
the truncated base 6240. Two hinge bodies are hidden to remove clutter from
the image. The
internal wiring leads 6250 are shown connected to the hinge contacts.
In one non-limiting embodiment, Figure 200 shows a completely assembled
horizontal
flower panel assembly with a concave transparent cover 6300.
An overview of supercapacitors and batteries is described above. To summarize:
supercapacitors are designed for quick charging, while batteries are designed
to provide long-
term energy. Supercapacitors, also called "ultracapacitors", are lightweight
and have a high
power density, meaning they can charge and discharge over a range of a
fraction of a second to
minutes. They maintain high efficiency over many years, millions of cycles and
a wide range of
temperatures, but are expensive and have limited storage. Conversely,
batteries have high energy
density, meaning they can charge and discharge over the course several minutes
to several hours.
They are less expensive and have more storage than supercapacitors. However,
their cycle life is
much shorter. Also, their operating temperature is limited and they degrade
quickly under heavy
loads such as intermittent solar power. By shifting load spikes to
supercapacitors, the life of the
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battery can be extended. And as supercapacitor storage increases, it will
complement batteries in
applications such as electric vehicles, speeding up charge times
significantly.
Capacitor storage is directly related to the surface area of their electrodes,
so a dense
stacking of honeycomb layers was introduced to increasing energy storage. The
density of the
layers within the supercapacitor and the number of layers may vary. These
layers are coated with
graphene, or equivalent nano-particles, creating additional surface area,
which leads to higher
storage capacity. The pattern of the electrodes may be an array of any
geometry, not necessarily
honeycomb. Also, the pattern on each layer may combine with the pattern on
subsequent layers
to make a specific 3D geometry to get more optimal surface area. The layers
are not restricted to
being parallel to the base/footprint of the pyramid. Nor are they restricted
to being parallel to
each other or flat. They may be curved.
A superconductive gel electrolyte is introduced between the layers which
increases
energy density, extending discharge time to match that of batteries, see
Figures 101-115. Until
the advent of Additive Manufacturing, also known as 3D printing, the intricate
geometries
required for these supercapacitors were not easily possible or they were
prohibitively expensive.
As the speed of this process increases, parts can move directly from prototype
to manufacturing,
driving costs down further.
They may be made in part or in full with specific 3D printing methods such as
Fused
Filament Fabrication (FFF), Fused Deposition Modeling (FDM), Stereolithography
(SLA),
Selective Laser Sintering (SLS) and Direct Metal Laser Sintering (DMLS). In
one non-limiting
embodiment, a process which cures SLA resin with oxygen and UV light increases
print speed
up 25X to 100X. This ultrafast additive method is geared toward full
production.
Supercapacitor layers may be made with chemically etched metal plates or foil
to
increase surface area/capacity.
Conventional manufacturing methods such as injection molding, thermoforming or
blow
molding may be used for various components in the capacitor cell. Conventional
manufacturing
methods may be used in conjunction with 3D printing to make these components.
An alternate, hybrid configuration which combines supercapacitor layers and
solar panel
layers in a single pyramid cell may be used where there is space, weight
and/or cost restrictions.
The bottom section of the pyramid space would function as a capacitor, while
the top would be
for solar panels. Other non-limiting configurations may substitute batteries
for capacitors in the
same space.
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NOTE: batteries may substitute or complement capacitor storage in any of the
various
embodiments.
Figure 201 shows an exploded view of a supercapacitor cell 6400. The
components
include: cell cover 6410, honeycomb lattice pyramid 6420, supercapacitor
casing 6430 and
supercapacitor connection rack 6440. Similar components are shown in Figures
109 and 111
including a cover 3110, a shell or casing 3160 and connection rack 3200. Those
components
have a different geometry than those in Figure 201.
Figure 202 isolates the following components: a positive serial post 6421,
positive
electrical leads 6422, a negative serial post 6423 and negative electrical
leads 6424. The posts
to .. 6421 and 6423 provide a serial connection for each of the honeycomb
layers, according to their
charge. The positive leads 6422 and the negative leads 6424 connect into posts
on the
supercapacitor casing 6430 which snap fit into the supercapacitor connection
rack 6440.
Figure 203 shows a supercapacitor casing 6430 sectioned in half to reveal the
negative
electrical leads 6424 as they're snap fit into the supercapacitor connection
rack. The negative
serial post 6423 is shown for reference. The rack has internal wiring to draw
current into two of
its own leads that snap fit into sockets on the pyramid wall body. These leads
connect to the
conductive elements in the bird-bone frame on the pyramid wall section.
Figure 204 shows the introduction of positive honeycomb layers 6425. In Figure
205 in
this non-limiting embodiment, eleven positive layers 6425 are shown. In Figure
206, eleven
negative honeycomb layers 6426 are highlighted to show a complete honeycomb
lattice pyramid
6420. Angled top and bottom views show detail in the lattice pyramid 6420.
Figure 207 shows a complete supercapacitor module 6500. In the non-limiting
embodiment shown here, the module is upside down and attached to an identical
module. In
other non-limiting embodiments, the opposite section may be a pyramid wall
panel. This wall
section may have multiple versions of solar panels in it.
Figure 208 shows a hybrid supercapacitor/post-less flower panel cell 6600. A
cell cover
6410 is shown at top. Under that are four nested panels 6110, 6120, 6130 and
6140. Under that
is a section view of the supercapacitor casing 6430 and a half-sized
honeycomb, lattice pyramid
6420. This configuration allows for solar collection and storage on a single
sided pyramid wall.
This can be for applications where vertical space or depth or weight is
limited.
Figure 209 shows a section view of a complete supercapacitor module 6500. At
the
bottom, two honeycomb lattice pyramids 6420 are shown. Connected at top is a
pyramid wall
housing with three configurations of solar panels. First, is a horizontal
stacking flower 5900. In
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this non-limiting embodiment, this cell in the pyramid wall housing has a
spherically concave
cover 6010 in one corner. Next to that is a "conventional" flower assembly
5700 and next to that
is a hybrid supercapacitor/post-less flower panel cell 6600.
Figure 210 shows the same complete supercapacitor module 6500 with a top cover
sectioned. In this non-limiting embodiment, the modular cover contains at
least one spherically
concave cover 6010 and two flat covers 6000. For weather protection,
restricted access to light
or aerodynamics, combinations of cover styles may range from 6000 to 6070 or
any geometric
shape based on the application.
The Pyramid Wall System has applications for both mobile installations and the
trucking
to industry. Mobile setups may be deployed for emergency power or shelters
in remote locations,
their containers formed from Pyramid Wall sections that are hinged in one or
more segments.
They may unfold and track the Sun or form a fixed structure. Within the
trucking industry,
tractor-trailers and other vehicles can use the Pyramid Wall System to offset
fuel costs in part or
in total. Tractor-trailers would benefit from several features of the Pyramid
Wall System
including, but not limited to the following:
1) Its unique geometry leads to increased stiffness and strength compared to
conventional walls and roofs of the same size. This strength can be augmented
with a bird-bone
lattice frame.
2) The configuration of solar panels within this geometry leads to increased
energy
collection compared to panels laid flat over the same footprint.
3) The ability to quickly charge advanced supercapacitors reduces the time
needed at
refueling stations, while supercapacitor/battery combinations allow a
controlled discharge of
power for hybrid or fully electric vehicles.
4) Drag reduction from dimpled covers can save at least 11% annual fuel costs.
Additional features such as the Fluke (see Figure 215) can reduce drag
further.
5) The Pyramid Wall System may provide power for refrigerated units, while the
closed
cell interior of the wall sandwich sections can provide thermal insulation.
6) Electroluminescent paint, electroluminescent tape or light-emitting diodes
(LED)s can
provide night time illumination and/or signage through the panels and/or
flukes. LEDs may be
individual components in an array, in a ribbon or in a sheet. They can also
use this illumination
feature to augment signaling. Their low power consumption allows them to draw
off of the
capacitor-battery portion of the Pyramid Wall System without an external
source. There are
several methods described above, such as, to coat the back side of the last
layer of panels or the
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inside faces of the pyramids. In one non-limiting embodiment, the top faces of
the pyramids on
the sides of a trailer may be coated for downward illumination.
7) Container sides may be retrofitted to house Pyramid Wall sections or
completely
constructed out of Pyramid Wall sections. They may include single sided wall
panels containing
solar cells or any of the combinations of solar panel-capacitors.
8) Pyramid Wall sections may have transparent covers for weather protection
and a
variety of dimple shapes and characteristics as shown in Figures 193-195 and
Figure 200. These
covers form side panels with shapes independently positioned and configured
for maximum drag
reduction. Some covers may have simple lens characteristics; either
conventional, Fresnel or
to lenticular based on the position of the Pyramid Cell. In addition,
pyramid cavities may have
uneven sides in order to achieve the maximum potential solar collection, based
on their position
within the wall. The covers may be individually formed or made in a complete
sidewall sheet. It
can be followed by a post process to allow individual sections to be replaced
in case of damage
or if reconfigured. The covers may have drag reducing "Flukes" on the leading
and trailing
edges. These flukes may be individually formed as well or made in a complete
sidewall sheet
with the ability to be replaced. Drag reduction covers may be used on existing
trailers without
the Pyramid Wall sections.
Figure 211 shows a fully assembled tractor trailer 6700 with the Pyramid Wall
System.
The dimpled covers are configurable and may be used without solar panels or
electrical storage
.. such as batteries or capacitors. The dimpled covers may also be used on
conventional trailer
sides without Pyramid Wall sections.
Figure 212 shows a standalone trailer frame 6710, three wall sections 4990, a
close-up of
the inside faces of a pyramid array 4950 and a close-up of the backside of a
wall section
showing a frame top with sockets 4970 and mounting plugs 4980. Wall sections
can be made in
various sizes and bonded together to make a complete trailer side or they can
be made as a single
panel, with or without connecting features or electrical features.
Figure 213 introduces a cab 6720 and two end, transparent dimpled covers 6730.
Other
non-limiting embodiments may include solar cell and capacitor/battery end
walls.
Figure 214 introduces two side transparent, dimpled walls 6740 and one top
transparent,
dimpled wall 6750. The dimple patterns on these walls are configurable and
adjusted based on
input from wind tunnel tests and 3D model simulations such as computational
fluid dynamics
(CFD).
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Figure 215 shows cropped, exploded and detailed views of several features on
the top
transparent, dimpled wall 6750. Included are circular dimpled panels, flat
panels, crescent
shaped dimpled panels and triangular shaped cavity seals. Nested above that
are small and large
aerodynamic "Flukes". Exploded from the leading edge is a row of three small,
aerodynamic
flukes 6760 and three large aerodynamic flukes 6770. To the left and above
that is a side view
showing the profile of a small fluke 6760 and a large fluke 6770 behind it. To
the right of that is
a cropped view from the back end of the panel highlighting crescent shaped
dimples 6025.
Exploded above that are three large flukes 6770. Their footprint is to be
aligned with crescent
shaped dimples, which in one non-limiting embodiment may be a pattern choice
based on
in) experimental data.
At the bottom left is a detail view of the top dimpled wall. A flat cover 6000
and
spherically concave cover 6010 are noted as well as a triangular shaped cavity
seal 6005 for a
flat cover and a triangular shaped cavity seal 6015 for a spherically concave
cover. In one, non-
limiting embodiment, these cavity seals will be simply an end feature of a
cover configuration,
e.g., seal 6005 is part of cover 6000, seal 6015 is part of cover 6010, etc.
Figure 216 shows a section view of the tractor-trailer showing a sample of the
solar
panel/supercapacitor wall. A cropped view normal to the section cut shows
capacitors and
flower panel wall cells. Transparent covers are removed to show a more
detailed section view of
the capacitor/flower assembly. An end view looking from back to front shows
alternating small
flukes 6760 and large flukes 6770.
In one non-limiting embodiment, the solar panel configuration may be a stacked
flower
assembly 5700 as shown in the end view. Diagonally below that and to the right
is a honeycomb
latticed pyramid 6420 as part of a supercapacitor. This shows a cross section
of a flower
panel/supercapacitor array. To the right is a detailed view of the trailer
section. Select covers are
removed to reveal features of the array (petals and post in the flower 5700
and honeycomb
features in the lattice 6420).
Figure 217 shows a view from the front of a sectioned tractor-trailer. An
exploded view
of some transparent wall covers reveals asymmetrical Pyramid Wall cells, where
the top sides
are shorter than the bottom. The cab 6720 is shown for reference. A detail of
an exploded area of
a side panel is shown with several flat covers 6000 removed. Directly behind
that is a sample of
asymmetrical panels. In one non-limiting embodiment, pyramid configuration
4585 with uneven
sides (shortened at the top) are used to best capture incident light from the
bottom rows on a
trailer. Panel sides and covers will be customizable.
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Figure 218 shows an angled view of a tractor-trailer with Pyramid Wall System
6700.
Customizable aerodynamic features are shown in context of the whole vehicle.
Sound walls are designed for the purpose of reflecting, diffusing or absorbing
sound
waves. For over fifty years they have been extensively used in the US as
highway noise barriers.
Residential and commercial developments have seen an increase of these
barriers as well. They
have been used for sound damping in concert halls and in studios where they
can mute specific
frequencies. They create the anechoic chambers in laboratories, which fully
absorb and isolate
all sound waves. Effectiveness, cost and esthetics are design factors, with
most of the tradeoff
between cost and effectiveness.
In general, the least effective but cheapest form of wall is reflecting, which
may be seen
on long stretches of highway. Reflecting walls may be sufficient in rural
areas, but generally
transfer noise to areas in front of it. Competing reflective walls on opposite
sides may actually
increase noise in an area.
Diffusing walls are the next most effective, but may have a more elaborate
shape and
higher cost. "S" shaped walls and walls with irregular geometric features fall
into this category;
they break up sound in front of it, not merely reflecting it to the other
side.
Absorbing walls are generally the most effective and most expensive. These
include
walls with acoustic foam, closed cell foam, pellets, earth and small rocks.
Many sound walls
have some combination of all three kinds of barrier.
The Pyramid Wall System is a natural candidate for two of these sound wall
categories:
diffusion and absorption. Its unique shape diffuses sound by reflecting it
within its array of
inverted pyramid faces.
In one non-limiting embodiment, H-beams are secured on concrete forms (for
example,
Sonotubes) which in turn are secured to footings. The Sonotube/footing
combination can then be
embedded in the ground, with a horizontal ground level support providing a
base and spacing
between the Sonotubes.
Back to back wall sections, as described in Figures 168-170, can form the
standalone
panels used to create an absorbing wall. The back to back wall sections slide
down between the
channels in the H-beams beginning with a start section, which has a row of
dummy panels at its
bottom. More sections are added until it reaches the top, which has a space to
hold a weather
cap.
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Before the cap is added material is then forced into the "sandwich gap"
between the
front and back. This material may include, but is not limited to: spray foam
insulation, closed
cell foam, acoustic foam, and recycled material including plastic and wood
pulp.
A lattice may be printed in the inside face of one of the standalone wall
sections, with the
sections joined later, to provide increased reinforcement. Plugs and sockets
may have drainage
ports for moisture and heat.
Pyramid Wall sections may be made in any of the processes, using any of the
materials
mentioned above. In particular, any of the wall sections made with composites
are an order of
magnitude or more lighter than if made of concrete.
A sound wall made up of Pyramid Wall sections may have empty pyramid spaces.
Pyramid spaces may have solar panels on one side, capacitor/battery
combinations on
the opposite or hybrid capacitor/solar panels on one side. Electroluminescent
paint,
electroluminescent tape and light-emitting diodes (LED)s on the outsides face
of the innermost
solar panels or the inside faces of the pyramid cells for nighttime use. LEDs
may be individual
components in an array, in a ribbon or in a sheet. Capacitor/battery
combinations can make these
lighted features self-sufficient.
Pyramid Wall sections joined by H-beams may be joined to form a continuous
stretch of
sound wall. Sound wall sections may be curved. In one non-limiting embodiment,
the inverted
faces of the pyramids may follow a curved backing shape in a design based on
acoustic criteria.
The curve may be "S" shape or compound.
Inside faces of the pyramids may be uneven or asymmetrical, based on acoustic
criteria
Solar power criteria may be a factor in shaping the inside pyramid faces as
well.
Figure 219 shows an exploded view of a sound wall section 6800. At the bottom
of the
left side image, footings 6820 are ready to be put in the ground. Concrete
Sonotubes 6830 are
.. directly on top and will be buried to their top. A ground wall support 6840
is put directly on top
of the Sonotubes 6830, its ends just covering the gap between posts. H-beams
6810 are joined
on top of the Sonotubes 6830, with rebar (not shown) sticking into it and all
the way until the
footing.
Four Back to Back Pyramid Wall sections 5200 are shown above the H-Beams 6810
ready to slide in. Detail on the bottom left shows a portion of a dummy panel
5220 at the bottom
of a Back to Back Pyramid Wall section 5200. The profile of an H-beam 6810 is
shown in that
detail view. Above that on the right is detail of the Pyramid Arrays 4950
(back and front) and
Wall Cap 6850 ready to secure the Pyramid Wall sections 5200.
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Figure 220 shows a completed sound wall section 6800. Figure 221 shows a
completed
sound wall section 6800 with a breakaway view exposing (in one non-limiting
embodiment)
closed cell foam 5210. In other configurations this insert may be pellets of
plastic, recyclables
including plastic, paper/pulp or concrete. Figure 222 shows a series of sound
wall 6900. These
segments may be of indefinite length, curved or angled, depending on design
criteria.
The Pyramid Wall System may be applied to structures of various sizes and
shapes.
They may also form self-contained structures to be used as stand-alone units
of various size and
shape. They may form arrays of indefinite length. They may use tracking
systems or be fixed.
The individual pyramid cells in the structure may have uneven sides and be
unlimited in size and
number. The base of this structure may be a regular or irregular polygon with
an unlimited
number of sides. Sides of the Pyramid Wall Structure may be flat or curved.
The pyramid cells
are then joined in a modular fashion within a pyramid shaped frame to create
the Pyramid Wall
Structure.
In one non-limiting embodiment, the involute surfaces of the Pyramid Wall
Structure
show a 119.6% increase in surface area over the base or footprint of the
pyramid. Another non-
limiting embodiment of the Pyramid Wall Structure may only use panels for the
base of the
pyramid with the sides removed. A wind skirt may be added around the perimeter
of these base
sections to help keep panels pressed to the roof during drafts. Air vents may
be added for
moisture and heat ventilation.
Figure 223 shows a standalone, Pyramid Wall Structure 7000. This may be a
standalone
unit, be used on top of a building or in an array on a solar farm.
Figure 224 shows an exploded view of the triangular sidewall of a Pyramid Wall
Structure. This side wall may have similar construction to the Pyramid Wall
4990. However, it
can be sectioned differently, so it has a unique number. In this non-limiting
embodiment, a nine
pointed wall section 7110, eight and seven point section 7120, six and five
point section 7130,
four and three point section 7140 and a two and one point section 7150 are
positioned to be
joined. A slotted base section 7210 is directly underneath and a base 7220
will connect to it.
Figure 225 shows detail of the slotted base section 7210 and base 7210 to be
connected.
Figure 226 shows a triangular sidewall 7100 assembled and ready to connect to
the slotted base
section 7210 and onto the base 7220. Figure 227 shows two reference views of a
triangular
sidewall 7100 assembled into a slotted base section 7210 and the base 7220
waiting to be
assembled. Figure 228 shows an assembly of four bases 7220, one triangular
sidewall 7100 into
one of the four slotted base sections 7210 and two frame member's 7230 ready
to assemble. In
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one non-limited embodiment these frame members may secure panels on the inside
of the
pyramid structure, so as to allow complete exposure of the panel edges and
sides to the Sun.
Figure 229 shows a completed Pyramid Wall Structure 7000 with its cap 7240
exploded over it.
Figure 230 shows a full building with its sides covered with single sided
Pyramid Wall
4990 sections. At the top are the base 7220 and slotted base 7210. Figure 231
shows a partially
assembled Pyramid Wall Building 7300. Frame members 7230 are shown exploded
with a cap
7240 just over them. Panels may be assembled one row at a time or one side at
a time. Figure
233 shows a fully assembled Pyramid Wall Building 7300. In this non-limiting
embodiment,
four Pyramid Wall Structures are shown on a roof. These structures are not
restricted to size,
shape or quantity.
Figure 233 shows a tracking Pyramid Wall Structure 7400. In this non-limiting
embodiment, the Pyramid structure may track the sun with two degrees of
freedom. Base
elements 7420 is connected to pivoting element 7410. Element 7410 can move in
one direction
and the Pyramid structure may be moved in a second, perpendicular direction.
In one non-limiting embodiment (not shown) back to back wall panels may be
used to
house capacitors/batteries inside the pyramid's structure. They may be in
arrays in a solar farm
and the shape of the individual cells may vary based on the optimum
performance of solar
collection.
Figure 234 shows a Flat Pyramid Wall Building 7500. In an exploded view above
roof
sections, wind skirts are positioned to be secured. In this non-limiting
embodiment, the panels,
sides, base, slotted base frame and cap are replaced by a Pyramid Wall 4990
secured by Wall
Sockets (5300) and an Aligning/Mounting Template/Fixture (5400). The perimeter
of these
panels is secured by a Wind Skirt 7510. This helps reduce strain on fasteners
and bonding agents
by taking advantage of downward drafts over buildings.
Figure 235 shows a detailed cropped view of the Wind Skirt 7510, Skirt Vent
Holes
7515 and a Pyramid Wall Section 4990. As in any of the configurations of
Pyramid Wall
System, electroluminescent paint, electroluminescent tape or light-emitting
diodes (LED)s may
be used with inverters in this system; either on the backs of panels or on the
inside faces of the
pyramids. LEDs may be individual components in an array, in a ribbon or in a
sheet.
Transparent covers for weather and or air dispersion may be used.
As described above, various embodiments provide a method and apparatus to
create
wall sections. These wall sections may then be used to quickly set up
pyramidal structures.
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Various operations described are purely exemplary and imply no particular
order.
Further, the operations can be used in any sequence when appropriate and can
be partially
used. Various operations described as individual steps may be combined into a
single
operation. Additionally, some operations described as individual steps may be
divided so as
to be performed as multiples steps. As used herein, the terms fig., Figure,
image and step may
be used interchangeably. For example, in some embodiments, the vacuum forming
shown in
Figure 3 may be done in a full vacuum chamber and the steps may vary. In other
embodiments,
the sheet may be clamped and cut at various steps before the final vacuum
forming step and
curing occurs. In still other embodiment, various Figures could be reordered
so as to take place
as another sequence of steps.
In one non-limiting embodiment of the sheet being formed into the shape of the
pyramids, after the last fold and cutting step, an infusion mesh may be placed
on top of the
material to wick resin. The mesh may be taped along the outside, with two
plastic connectors
loosely placed for a vacuum hose on opposite sides. A slightly oversized
vacuum bag (for
example, a single sided sheet of clear bagging material) can then be placed
over the material and
taped down with vacuum bagging tape.
An incision may be made above each connector. One allows a hose to draw resin
from a
reservoir. The other connects a hose which is attached to a vacuum pump.
Initially, the reservoir
may be clamped off and a full vacuum may be pulled through the bag. Then, the
hose at the
pump end may be clamped off as well. After it is determined that there are no
leaks, the clamp at
the reservoir end may be opened and the resin may be drawn through the
infusion mesh. Then
both hoses may be clamped off again. The vacuum forming sheet may be allowed
to cure over
the next 24 hours to make the finished housing.
An embodiment provides a method for collecting and storing solar energy using
pyramid
shaped cavities and associated elements in singular units or arrays. The
method uses reflectivity
among the panels to maintain the same power output as if they were laid flat.
This allows for
installations where the mounting area is restricted. The angle of each side
with respect to the
base of the pyramid ranges between 5 and 85 . The base or "footprint" of
these pyramids may
be regular or irregular polygons such as a diamond or rhombus shape. However,
the number of
sides are unrestricted and the pyramid sides may be uneven. Sections that have
restricted access
to sunlight may have uneven sides to best capture incident light.
Inverted pyramids have their sides spaced away from building surfaces allowing
natural
air flow to cool cells, increasing efficiency as heat is reduced. The Pyramid
Wall System is not
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limited by the number of pyramid "cells" or "modules" and that the cells or
modules are
scalable.
Another embodiment provides a method for arranging solar panels, The solar
panels
may be assembled flat and hinged, creating a cross shaped pattern bonded or
snap fit to the
inside faces of pyramids. Solar panels may be flexible, formed as a cross
shaped flat pattern and
"4D" folded into a pyramid shape to be bonded or fit to the inside faces of
pyramids. Solar
panels may be single sided or bifacial and made with conventional
manufacturing methods or
3D printed. They may be transparent in the visible spectrum and made of
inorganic materials
such as perovskite or organic salts. They may use graphene or equivalent
superconductive
material to create transparent nanowires or to coat conventional electrical
contacts. Panel
contacts may be arranged in a dense geometric pattern such as (but not limited
to) a honeycomb
shape, to increase contact surface area and efficiency. The panels and its
contacts may be made
with conventional manufacturing methods, 3D printed with conductive material
or a
combination of the two.
Solar panels may be secured in a mounting post which will allow a conductive
path
through a central location. Mounting post wiring layers may contain
embedded/over-molded
wires. They may house molded, machined or 3D printed channels or conduits with
inserted leads
to create the wiring layers. The layers may have 3D printed conductive leads.
The channels or
conduits in the mounting posts may be sprayed or electroplated with conductive
material or
superconductive material such as graphene or equivalent. They may be coated
with conductive
or superconductive gel.
Wiring layers may be produced with any combination described herein and
stacked for
multiple sets of panels. The mounting post body may be extended with slots
added to allow for
the stacking of multiple panel arrays. Panels transparent to visible light (or
specific wavelengths)
may be stacked within the pyramid space, each layer positioned to absorb a
specified range of
wavelengths. Panel layers may be flat and parallel to each other or flat and
independently
oriented/angled/positioned to each other. Panel layers me curved to foiiii any
geometric or non-
geometric shape. The may be concentrically nested or independently
oriented/angled/positioned
to each other. They may be staggered and offset, like the petals of a rose.
Panels may have a transparent outer surface that functions as any type of
conventional
simple lens, lenticular lens or Fresnel lens. These lenses may be of a variety
of shapes and have
a variety of purposes including focusing, defocusing and redirecting light.
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Panels transparent or semi-transparent to visible light may have their outside
faces
coated with electroluminescent paint, electroluminescent tape or light-
emitting diodes (LED)s.
LEDs may be individual components in an array, in a ribbon or in a sheet. This
will be for
nighttime use if transparent cells are used. These lighted faces will be self-
sustaining, drawing
power through an inverter connected to electrical storage such as
supercapacitors and/or
batteries in the Pyramid Wall modules. Electroluminescence may be powered by
the capacitor or
solar panel.
A further embodiment provides wall sections vacuum formed over molds using
composite sheets. These sections can range from small modular "A" and "B"
mating sections to
full wall panels. Wall sections may be made through additive manufacturing,
also known as 3D
printing. They may be made in part or in full with specific 3D printing
methods such as Fused
Filament Fabrication (FFF), Fused Deposition Modeling (FDM), Stereolithography
(SLA),
Selective Laser Sintering (SLS) and Direct Metal Laser Sintering (DMLS). (One
ultrafast
additive process geared toward full production uses SLA resins and/or SLA
cured with oxygen
and UV light). Wall sections may be FFF/FDM 3D printed using chopped carbon
fiber with a
thermoplastic base or continuous strands of fiber with thermoplastic base. The
chopped carbon
fiber and thermoplastic base may be in the form of pellets, filament or
combination thereof
The Pyramid Wall System may be FFF/FDM 3D printed in part or in full by
extruders
on robotic arms, allowing non-orthogonal movement to match the geometry of the
sections and
speed up the process for manufacturing. The robotic arms may travel in
individual or multiple
units on a conventional linear rail or linear gantry system. Robotic arms may
travel in a
curvilinear motion; individual or multiple arms moving independently or on a
compound curve
track. Production systems may use combinations of robotic arms as well as
extruders on gantries
as in conventional FFF or FDM printing.
Molds or forms for composite wrapping may be 3D printed using additive
manufacturing processes such as FFF, FDM, SLA, SLS or DMLS. Molds may be made
with a
CNC milling machine or router. Molds may be made by pouring a variety of
material (including
but not limited to plastic and concrete) between back-to-back wall sections.
Pyramid Wall sections may be made from Vacuum formed thermoplastic sheets,
injection molded or rotomolded
Wall sections may be printed flat, with a living hinge to move into shape,
either
manually or with an outside stimulus, to be stacked for storage and
transportation.
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Substitute materials for wrapping include: fiberglass and Kevlar. Substitute
material for
FFF/FDM 3D printing includes fiberglass and Kevlar (strands or chopped),
thermoplastics (by
themselves), concrete, cement, wood pulp, composite wood with binder, and
recyclables. These
materials can be fed as pellets, filaments or combinations thereof and
extruded through the 3D
printer nozzle. Substitute materials for various mold process include: wood
pulp/composite
wood, recyclable material (including plastic) and composite embedded
thermoplastics, cement
or concrete.
Walls may be milled or routed out of plastic or wood.
Walls may be made out of sheet metal.
Any of the components in the Pyramid Wall System may be completely
manufactured or
in combination with any of the processes described herein.
Another embodiment provides a method of joining Pyramid Wall sections back to
back.
In standalone sections, separate wall sections can be connected back to back
with fasteners. The
axis of the posts and sockets may be aligned as posts are fit into sockets to
be secured. Sockets
may instead have semi-circular cutouts so that posts may slide in.
These standalone sections have space which can be filled with closed cell foam
or pellets
of a variety of material (including recycled plastic or paper) or cement. This
filler material may
be used for thermal insulation, sound absorption or both. A 3D printed lattice
can be inserted
between sections and reinforced with material such as closed cell foam. The
lattice may be
printed in the inside face of one of the standalone wall sections, with the
sections joined later.
Plugs and sockets can have aligned drainage ports for moisture and heat.
A further embodiment provides a method to connect single sided Pyramid Wall
sections
to walls. A single sided Pyramid Wall section has their center posts form an
electrical hub which
connects the solar panel leads. This hub then connects into a cavity in a Wall
Socket which has
been mounted onto a wall or support surface. A fastener protrudes from the hub
which is secured
into an embedded, threaded insert in the Wall Socket cavity. The cavity has
electrical contacts
which then draw power from the hub and transfer it to a wiring harness or
electrical conduits in
an Aligning/Mounting Template/Fixture. Cutout sections in the
Aligning/Mounting
Template/Fixture have the same profile as a Wall Socket. Notches in the cutout
sections provide
relief for contact nipples in the Wall Sockets.
The Aligning/Mounting Template/Fixture may also be used as a temporary
mounting
template, to align the wall sockets before they're fastened or bonded into a
wall. The template
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may have no electrical conduits or embedded wiring itself. It would be for
Wall Socket
alignment and then be removed.
As a permanent mounting fixture, the Aligning/Mounting Template/Fixture may be
with
or without electrical conduits or embedded wiring. It may be completely
supported by sockets
after they are fastened or bonded into a wall. The Aligning/Mounting
Template/Fixture may be
fastened or bonded independently to provide additional support for the Pyramid
Wall Section.
The Wall Sockets and Aligning/Mounting Template/Fixture may be machined,
routed,
laser cut, water cut or molded through various methods including injection
molding. They may
be formed through additive manufacturing, also known as 3D printing. They may
be made in
part or in full with specific 3D printing methods such as Fused Filament
Fabrication (FFF),
Fused Deposition Modeling (FDM), Stereolithography (SLA), Selective Laser
Sintering (SLS)
and Direct Metal Laser Sintering (DMLS).
Electrical contacts in the Wall Sockets and conduits in the Aligning/Mounting
Template/Fixture may be a path for insulated wiring, over-molded wires or 3D
printed with
conductive material. The conduits may be coated with superconductive material
such as
Graphene or equivalent and/or filled with superconductive gel or any
combination thereof.
The Wall Sockets and Aligning/Mounting Template as a permanent fixture may
have
mounting holes to allow fastening to a mounting surface. They may be secured
with bonding
compound or a combination thereof
In one non-limiting embodiment, the Pyramid Wall System can take advantage of
space
within the pyramid space to position layers of semitransparent or transparent
cells/panels to
absorb specified wavelengths of visible and/or non-visible light. The first
layer of solar panels
may be single sided or bifacial and fastened to the inside faces of the
pyramid housing. They
may use graphene or equivalent superconductive material to create transparent
nanowires or to
coat conventional electrical contacts. Panel contacts may be arranged in a
dense geometric
pattern such as (but not limited to) a honeycomb shape, to increase contact
surface area and
efficiency.
Both the first and subsequent panel layers may be transparent in the visible
spectrum and
made of inorganic materials such as perovskite or organic salts. They could be
stacked like
petals of a flower around a post or -stem". The stacking may be flat and form
the sides of offset
pyramids around a stem or the sides may be curved and/or overlap like the
petals of a rose. Panel
layers may be flat and parallel to each other or flat and independently
oriented/angled/positioned
to each other. Panel layers may be curved to form any geometric or non-
geometric shape. The
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may be concentrically nested or independently oriented/angled/positioned to
each other. They
may be staggered and offset, like the petals of a rose. Individual panels may
be split into two or
more sections and positioned independently.
Panel layers may be coated with anti-reflective and/or polarizing compounds.
They may be made with conventional manufacturing methods or through additive
manufacturing, also known as 3D printing. They may be made in part or in full
with specific 3D
printing methods such as Fused Filament Fabrication (FFF), Fused Deposition
Modeling
(FDM), Stereolithography (SLA), Selective Laser Sintering (SLS) and Direct
Metal Laser
Sintering (DMLS). In one non-limiting embodiment, a process which cures SLA
resin with
to
oxygen and UV light increases print speed up 25X to 100X. This ultrafast
additive method is
geared toward full production.
The panels and its contacts may be made with conventional manufacturing
methods, 3D
printed with conductive material or a combination of the two. Solar panels may
be secured in a
mounting post which will allow a conductive path through a central location.
The mounting post
may be manufactured with conventional manufacturing methods such as injection
molding or
3D printed in any of the various methods described above or combinations
thereof.
The conductive paths that make up the mounting post wiring layers may contain
embedded/over-molded wires. They may house molded, machined or 3D printed
channels or
conduits with inserted leads to create the wiring layers. The layers may have
3D printed
conductive leads. The channels or conduits in the mounting posts may be
sprayed or
electroplated with conductive material or superconductive material such as
graphene or
equivalent. They may be coated with conductive or superconductive gel.
In one non-limiting embodiment, transparent superconductive capacitors could
be used
between transparent cell layers for storage.
The Cross Panel/Flower assembly can have a Mounting/Flower Post assembly that
allows multiple sets of panels to be stacked. The Flower Post's Connection may
be used to
stabilize and secure the panels in the Pyramid Wall cavities. A Flower Post
assembly includes
the post's base or hub, the post body, a mounting fastener and an access cap.
In one non-limiting
embodiment, it is used to mount the solar array into a pyramid wall section
and into a wall
socket. It may be coated for reflectivity and contain electrical paths or
conduits which may be
over-molded, inserted or 3D printed with electrical leads. It may have a
different profile from the
diamond shape shown, such as circular, oval or any regular or irregular
polygon, it may taper
and may be scaled differently to account for space restriction. The Flower
Post's hub is below
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the post body with a mounting fastener in place in the body's countersunk
hole. Panel recesses
along the outside of the post's body position the different levels of panels.
Snap fit sockets allow
snap fits on the access cap to secure it in place and protect the fastener.
Access cap recesses
allow tool access for quick release.
The first level of wiring connects to the Cross Panel hinges. Negative and
positive leads
connect through the mounting hub. Multiple levels of wiring connect multiple
levels of stacked
panels.
A completed Flower assembly may be folded into a pyramid shape, its outside
surfaces
coated with electroluminescent paint, electroluminescent tape or light-
emitting diodes (LED)s.
LEDs may be individual components in an array, in a ribbon or in a sheet.
Panels may be
transparent or semitransparent to different wavelengths depending on the
requirements of the
electroluminescent coating or LEDs.
In another non-limiting embodiment, each panel may form a single, flat layer
around the
mounting post, where their exposed faces are parallel to the footprint of the
pyramid. Each layer
may be curved and concentrically nested around the mounting post. Each layer
may be equally
spaced or spaced differently along the mounting post. Each layer may be angled
independently
from each other or in any combination thereof.
Tabs with electrical contacts may be secured in the mounting post slots; their
exposed
edges to connect the leads on the solar panels. They may be secured with
fasteners, snap fits,
bonding agents or any combination, thereof.
Panels may be coated with anti-reflective and/or polarizing compounds.
In this non-limiting embodiment, a first layer horizontal panel, has an
exposed face that
is oriented parallel to the pyramid's base or footprint. The edges of a
clearance hole in the
horizontal panel will be positioned just above the panel recesses in the
flower post. Connecting
tabs fit into the recesses to be bonded or fastened to the first layer
horizontal panel. Subsequent
panels may be assembled first, working toward the top. The first to be
assembled on top of the
cross panels may be the bottom panel with connecting tabs. Consecutive layers
are assembled
until the top layer panel and its connecting tabs. The assembly is then folded
into a pyramid
shape, its outside surfaces coated with electroluminescent paint,
electroluminescent tape or
LEDs.
In several non-limiting embodiments, transparent covers may be used for
various
purposes within the Pyramid Wall System. They may be for protection from
weather, to provide
an aerodynamic surface or to aid in the collection or dispersion of light. The
geometry of the
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covers may be flat, indented or protruding and be of varying shapes. They may
cover individual
cells, small panel sections or large arrays. They may be uniform or mixed
depending on the
application.
Covers may be made from a number of different materials transparent to various
wavelengths of visible and non-visible light. These include but are not
limited to glass,
transparent polymers, transparent inorganic polymers, transparent epoxy resin,
transparent
ceramics and combinations thereof. These materials may be treated with
transparent silica
coatings, transparent epoxy or transparent nano-coatings for protection.
Covers forming a protective barrier for solar panels may also provide
protection for
structures in windy areas. They may reduce drag when used to shield solar
panels on moving
vehicles. Data from wind tunnel tests and computer analysis such as
computational fluid
dynamics (CFD) will determine the specific geometry of a cover segment, as
well as the
arrangement of these segments over a large array.
As the Pyramid Wall System may be exposed to extreme weather conditions,
moisture
and heat ventilation ports are to be introduced in various components in the
wall sections. They
may include side walls, edges comers, posts and mounting sockets on the
Pyramid Wall and
corners and edges on the covers.
Covers may perfo, __________________________________________________________
in a dual function as solar cells transparent in the visible spectrum and
made of inorganic materials such as perovskite or organic salts. They may use
graphene or
equivalent superconductive material to create transparent nanowires or to coat
conventional
electrical contacts. Panel contacts may be arranged in a dense geometric
pattern such as (but not
limited to) a honeycomb shape, to increase contact surface area and
efficiency.
Covers may function as any type of conventional simple lens, lenticular lens
or Fresnel
lens. These lenses may be of a variety of shapes and have a variety of
purposes including
focusing, defocusing and redirecting light. In one non-limiting embodiment a
solar cell cover
may have gradient wave patterned, refraction steps.
Covers may be coated with anti-reflective and/or or polarizing compounds.
Covers may be made as individual units for individual pyramid cells. They may
be made
as small modular sections or complete panels. Modular sections or complete
panels may have
custom shaped areas to secure over individual pyramid cells with break-away
features added for
individual units. In this way, only damaged units need to be replaced.
Covers may be made through conventional methods used for producing clear
plastic
sheets including extrusion, casting, blown film, injection molding and
thermoforming.
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Breakaway sections may be designed as molded features or added with a
secondary
manufacturing process such as water jet cutting, laser trimming or cutting
blades.
Covers may also be made through additive manufacturing, also known as 3D
printing.
They may be made in part or in full with specific 3D printing methods such as
Fused Filament
Fabrication (FFF), Fused Deposition Modeling (FDM), Stereolithography (SLA),
Selective
Laser Sintering (SLS) and Direct Metal Laser Sintering (DMLS). In one non-
limiting
embodiment, a process which cures SLA resin with oxygen and UV light increases
print speed
up 25X to 100X. This ultrafast additive method is geared toward full
production.
Breakaway sections in 3D printed parts may be made as a design feature using a
single
material. Breakaway sections may also be formed from the grooves/cavities
created after the
removal of 3D print support material. They may instead be added as a secondary
manufacturing
process such as water jet cutting, laser trimming or cutting blades.
Covers may be used on horizontal petal setups, with and without posts.
Additionally,
they can be used in any of the solar panel variations, as well as combinations
of capacitors and
batteries.
The access cap for a flower post may be truncated for clearance based on the
geometry
of the cover. A center screw may be used to secure the cover along with snap
fit features in the
corners.
The cover for a single pyramid cell has many variations. Several non-limiting
embodiments include a flat cover, a spherically concave cover, an oval concave
cover, a
teardrop concave cover, a spherically concave cover with a lens, a spherically
convex cover, an
oval convex cover and a teardrop convex cover are shown. The lens feature is
not limited to the
spherically concave variation, nor any of the variations in these figures. The
lens shape may be
any variation of conventional simple lens or Fresnel lens. The material for
any of the covers may
be an optically clear compound, transparent solar cells, transparent
capacitors or any
combination thereof.
In another non-limiting embodiment, an alternate version of the horizontal
stacking
flower removes the mounting post for stacking. This allows for a simpler
construction of panels
and more exposed surface area to light. Panel layers may be flat and parallel
to each other or flat
and independently oriented/angled/positioned to each other. Panel layers may
be curved to form
any geometric or non-geometric shape. They may be concentrically nested or
independently
oriented/angled/positioned to each other.
Panel layers may be coated with anti-reflective and/or or polarizing
compounds.
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Corners of the panels may provide electrical contact through leads along the
inside edges
of the pyramid cell or the edges between the sides of folded cross panels. A
simplified version of
a truncated mounting post can draw current from the inside edge leads into a
central location
(not shown).
The non-post, stacking flower has nested panels press fit into the cross panel
sides.
Electrical contacts may be at the outer corners of the horizontal panels with
the edges of the
cross panels providing a serial connection. The cross panels may have groove
features on the
inside face to hold the horizontal panels when folded in place or they may be
bonded or a
combination of the two. The panels may be flat or curved and may be positioned
in various
orientations within the pyramid cavity, not necessarily parallel to the
footprint/base of the
pyramid. The hub base is used to support the cross panel hinges. The hub body
provides a wiring
path as in the other designs and support for the hinge contacts. It has a low
profile as it is not
used to support flower petals. A mounting fastener connects through hub body,
which has a
countersunk through hole to position it.
Electric leads from the wiring path connect through the hub base. The hub base
nests the
hub body and the mounting fastener and the internal wiring leads connects to
the hinge contacts.
The backside of the cross panels may be coated with electroluminescent paint,
electroluminescent tape or LEDs.
Supercapacitors are designed for quick charging, while batteries are designed
to provide
long-term energy. Supercapacitors, also called "ultracapacitors" are
lightweight and have a high
power density, meaning they can charge and discharge over a range of a
fraction of a second to
minutes. They maintain high efficiency over many years, millions of cycles and
a wide range of
temperatures, but are expensive and have limited storage. Conversely,
batteries have high energy
density, meaning they can charge and discharge over the course several minutes
to several hours.
They are less expensive and have more storage than supercapacitors. However,
their cycle life is
much shorter. Also, their operating temperature is limited and they degrade
quickly under heavy
loads such as intermittent solar power. By shifting load spikes to
supercapacitors, the life of the
battery can be extended. And as supercapacitor storage increases, it will
complement batteries in
applications such as electric vehicles, speeding up charge times
significantly.
Capacitor storage is directly related to the surface area of their electrodes,
so a dense
stacking of honeycomb layers was introduced as a method of increasing energy
storage. The
density of the layers within the supercapacitor and the number of layers may
vary. These layers
are coated with graphene, or equivalent nano-particles, creating additional
surface area, which
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leads to higher storage capacity. The pattern of the electrodes may be an
array of any geometry,
not necessarily honeycomb. And the pattern on each layer may combine with the
pattern on
subsequent layers to make a specific 3D geometry to get optimum surface area.
The layers are
not restricted to being parallel to the base/footprint of the pyramid. Nor are
they restricted to
being parallel to each other or flat. They may be curved.
A superconductive gel electrolyte is introduced between the layers which
increases
energy density, extending discharge time to match that of batteries. Until the
advent of Additive
Manufacturing, also known as 3D printing, the intricate geometries for these
supercapacitors
was not workable or they were prohibitively expensive. As the speed of this
process increases,
parts can move directly from prototype to manufacturing, driving costs down
further.
They may be made in part or in full with specific 3D printing methods such as
Fused
Filament Fabrication (FFF), Fused Deposition Modeling (FDM), Stereolithography
(SLA),
Selective Laser Sintering (SLS) and Direct Metal Laser Sintering (DMLS). In
one non-limiting
embodiment, a process which cures SLA resin with oxygen and UV light increases
print speed
up 25X to 100X. This ultrafast additive method is geared toward full
production.
Supercapacitor layers may be made with chemically etched metal plates or foil
to
increase surface area/capacity.
Conventional manufacturing methods such as injection molding, thermoforming or
blow
molding may be used for various components in the capacitor cell. Conventional
manufacturing
methods may be used in conjunction with 3D printing to make these components.
An alternate, hybrid configuration which combines supercapacitor layers and
solar panel
layers in a single pyramid cell may be used where there is space, weight
and/or cost restrictions.
The bottom section of the pyramid space would function as a capacitor, while
the top would be
for solar panels. Other non-limiting configurations may substitute batteries
for capacitors in the
same space.
NOTE: batteries may substitute or complement capacitor storage in any of the
various
embodiments.
The components of a supercapacitor cell include: cell cover, honeycomb lattice
pyramid,
supercapacitor casing and supercapacitor connection rack. Electrical contacts
include the
following: a positive serial post, positive electrical leads, a negative
serial post and negative
electrical leads. The posts provide a serial connection for each of the
honeycomb layers,
according to their charge. The positive leads and the negative leads will
connect into posts on the
supercapacitor casing which will snap fit into the supercapacitor connection
rack. The rack has
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internal wiring to draw current into two of its own leads that snap fit into
sockets on the pyramid
wall body. These leads then connect to the conductive elements in the bird-
bone frame on the
pyramid wall section.
In one non-limiting embodiment multiple positive honeycomb layers combine with
negative honeycomb layers to complete a honeycomb lattice pyramid. In one non-
limiting
embodiment, a module is upside down and attached to an identical module. In
other non-limiting
embodiments, the opposite section may be a pyramid wall panel. Wall section
may have
multiple versions of solar panels and covers in it, including a hybrid
supercapacitor/post-less
flower panel cell. This configuration allows for solar collection and storage
on a single sided
to pyramid wall in applications where vertical space or depth or weight is
limited. Other
configurations may include a horizontal stacking flower, conventional flower
or any
combination thereof.
An alternate, hybrid configuration which combines supercapacitor layers and
solar panel
layers in a single pyramid cell may be used where there are space, weight
and/or cost
restrictions. The bottom section of the pyramid space would function as a
capacitor, while the
top would be for solar panels.
This configuration allows for solar collection and storage on a single sided
pyramid wall.
This can be for applications where vertical space or depth or weight is
limited.
Other non-limiting configurations may substitute batteries for capacitors in
the same
space.
In a further embodiment, the Pyramid Wall System has applications for both
mobile
installations and the trucking industry. Mobile setups may be deployed for
emergency power or
shelters in remote locations, their containers formed from Pyramid Wall
sections that are hinged
in one or more segment. They may unfold and track the Sun or form a fixed
structure. Within
the trucking industry, tractor-trailers and other vehicles can use the Pyramid
Wall System to
offset fuel costs in part or in total. Tractor-trailers would benefit from
several features of the
Pyramid Wall System including, but not limited to the following:
1) Its unique geometry leads to increased stiffness and strength compared to
conventional walls and roofs of the same size. This strength can be augmented
with a bird-bone
lattice frame.
2) The configuration of solar panels within this geometry leads to increased
energy
collection compared to panels laid flat over the same footprint.
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3) The ability to quickly charge advanced supercapacitors reduces the time
needed at
refueling stations, while supercapacitor/battery combinations allow a
controlled discharge of
power for hybrid or fully electric vehicles.
4) Drag reduction from dimpled covers can save at least 11% annual fuel costs.
Additional features such as the Fluke can reduce drag further.
5) The Pyramid Wall System may provide power for refrigerated units, while the
closed
cell interior of the wall sandwich sections can provide thermal insulation.
6) Electroluminescent paint, electroluminescent tape or light-emitting diodes
(LED)s can
provide night time illumination and/or signage through the panels and/or
flukes. LEDs may be
it) individual components in an array, in a ribbon or in a sheet. They can
also use this illumination
feature to augment signaling. Their low power consumption allows them to draw
off of the
capacitor-battery portion of the Pyramid Wall System without an external
source. A luminescent
layer can be a coat the back side of the last layer of panels or the inside
faces of the pyramids. In
one non-limiting embodiment, the top faces of the pyramids on the sides of a
trailer may be
coated for downward illumination.
7) Container sides may be retrofitted to house Pyramid Wall sections or
completely
constructed out of Pyramid Wall sections. They may include single sided wall
panels containing
solar cells or any combinations of solar panel-capacitors.
8) Pyramid Wall sections may have transparent covers for weather protection
and a
variety of dimple shapes. These covers can form side panels with shapes
independently
positioned and configured for maximum drag reduction. Some covers may have
simple lens
characteristics; either conventional, Fresnel or lenticular based on the
position of the Pyramid
Cell. In addition, pyramid cavities may have uneven sides in order to achieve
the maximum
potential solar collection, based on their position within the wall. The
covers may be
individually formed or made in a complete sidewall sheet. It would be followed
by a post
process to allow individual sections to be replaced in case of damage or if
reconfigured. The
covers may have drag reducing "Flukes" on the leading and trailing edges.
These flukes may be
individually formed or made in a complete sidewall sheet with the ability to
be replaced. Drag
reduction covers may be used on existing trailers without other features of
the Pyramid Wall
sections.
For a fully assembled tractor trailer with the Pyramid Wall System, dimpled
covers are
configurable and may be used without solar panels or electrical storage such
as batteries or
capacitors. The dimpled covers may also be used on conventional trailer sides
without Pyramid
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Wall sections. In one non-limiting embodiment, a standalone trailer frame,
three wall sections
the length of a trailer and two wall sections to fit the ends of a trailer are
assembled. Wall
sections can be made in various sizes and bonded together to make a complete
trailer side or
they can be made as a single panel, with or without connecting features or
electrical features.
Two side transparent, dimpled covers; one top transparent, dimpled covers and
two end,
transparent dimpled covers are added. The dimple patterns on these walls are
configurable and
optimized based on input from wind tunnel tests and 3D model simulations such
as
computational fluid dynamics (CFD). Also, the size, shape and disposition of
aerodynamic
flukes along the leading and trailing edges of the trailer may be configured
based on the intended
it) use. Their footprint can be aligned with dimples, which in one non-
limiting embodiment may be
a pattern choice based on experimental data. Triangular shaped cavity seals
for covers of a
variety of shape fill the contours at the edges of the trailer. In one, non-
limiting embodiment,
these cavity seals are a feature of a cover configuration.
In one non-limiting embodiment, a pyramid configuration with uneven sides
(e.g.,
shortened at the top) can be used to capture incident light from the bottom
rows on a trailer.
Panel sides and covers can also be customizable.
Any of the operations described that form part of the presently disclosed
embodiments
may be useful machine operations. Various embodiments also relate to a device
or an
apparatus for performing these operations. The apparatus can be specially
constructed for the
required purpose, or the apparatus can be a general-purpose computer
selectively activated or
configured by a computer program stored in the computer. In particular,
various general-
purpose machines employing one or more processors coupled to one or more
computer
readable medium can be used with computer programs written in accordance with
the
teachings herein, or it may be more convenient to construct a more specialized
apparatus to
perform the required operations.
The foregoing description has been directed to particular embodiments.
However,
other variations and modifications may be made to the described embodiments,
with the
attainment of some or all of their advantages. Modifications to the above-
described systems
and methods may be made without departing from the concepts disclosed herein.
Accordingly, the invention should not be viewed as limited by the disclosed
embodiments.
Furthermore, various features of the described embodiments may be used without
the
corresponding use of other features. Thus, this description should be read as
merely
illustrative of various principles, and not in limitation of the invention.
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