Note: Descriptions are shown in the official language in which they were submitted.
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Injection Molded, Blow Molded, and Rotational Molded Articles
that Integrally Incorporate a Photovoltaic Device,
and Method and System for Producing Such Articles
Cross-Reference to Related Applications
[0001] This patent application claims priority and benefit: from US
63/106,666, filed on
October 28, 2020, which is hereby incorporated by reference in its entirety;
and also, from US
17/353, 867, filed on June 22, 2021, which is hereby incorporated by reference
in its entirety.
Field
[0002] Some embodiments relate to the field of solar panels and
photovoltaic (PV) devices.
Background
[0003] The photovoltaic (PV) effect is the creation of voltage and electric
current in a
material upon exposure to light. It is a physical and chemical phenomenon.
[0004] The PV effect has been used in order to generate electricity from
sunlight. For
example, PV solar panels absorb sunlight or light energy or photons, and
generate current
electricity through the PV effect.
Summary
[0005] Some embodiments provide an injection-molded article or a blow-
molded article or
a rotational-molded article, having a Photovoltaic (PV) cell or a PV device
that is integrally
embedded therein and/or that is integrally incorporated therein; as well as
methods and systems
for producing such articles.
[0006] Injection molded, blow molded, and rotational molded articles that
integrally
incorporate a photovoltaic device, and method and system for producing such
articles. A
method includes: placing an operable photovoltaic device at an inner-side of a
mold cavity of
a mold; performing injection molding or blow molding or rotational molding of
raw plastic
materials or raw polymeric materials; and thus forming a single, monolithic,
unified, molded
article that integrally holds therein or thereon the operable photovoltaic
device.
[0007] Some embodiments may provide other and/or additional benefits and/or
advantages.
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Brief Description of the Drawings
[0008] Fig. 1 is a flow-chart of a method of producing via injection
molding a plastic or
polymeric article having integrated PV device(s), in accordance with some
embodiments.
[0009] Fig. 2 is a flow-chart of a method of producing via blow molding a
plastic or
polymeric article (e.g., a hollow or partially-hollow plastic or polymeric
article) having
integrated PV device(s), in accordance with some embodiments.
[0010] Fig. 3 is a flow-chart of a method of producing via rotational
molding a plastic or
polymeric article (e.g., a hollow or partially-hollow plastic or polymeric
article) having
integrated PV device(s), in accordance with some embodiments
[0011] Figs. 4A to 4G are schematic illustrations demonstrating components
and
operational steps of an injection molding system, in accordance with some
demonstrative
embodiments.
[0012] Figs. 5A to 5C are illustrations of several prior art hybrid non-
monolithic products.
[0013] Figs. 6A to 6F are schematic side-view illustrations of several
monolithic molded
articles, in accordance with some embodiments.
Detailed Description of Some Demonstrative Embodiments
[0014] Some embodiments provide an injection-molded article or a blow-
molded article or
a rotational-molded article, having a Photovoltaic (PV) cell or a PV device
that is integrally
embedded therein and/or that is integrally incorporated therein; as well as
methods and systems
for producing such articles.
[0015] A solar cell, or photovoltaic (PV) cell, is a device that converts
the energy of light
or sunlight or photons directly into electricity by the photovoltaic effect, a
physical and
chemical phenomenon. Commonly used solar cells are configured as a large-area
p¨n junction
made from silicon. Other solar cell types are, for example, thin film like
CdTe or CIGS, organic
solar cells, dye sensitized solar cells, perovskite solar cells, quantum dot
solar cells etc.
[0016] Some solar cells operate according to the following: (1) Photons in
sunlight hit the
solar panel and are absorbed by semiconducting materials, such as silicon; (2)
Electrons are
excited by the photons from their current molecular/atomic orbital in the
semiconducting
material; (3) Once excited an electron can either dissipate the energy as heat
and return to its
orbital or travel through the cell until it reaches an electrode; (4) Current
flows through the
material to cancel the potential and this electricity is captured. The
chemical bonds of the solar
cell material are important for this process to work, and usually silicon is
used in two regions,
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one region being doped with boron, the other phosphorus. These regions have
different
chemical electric charges and subsequently both drive and direct the current
of electrons
towards a relevant electrode.
[0017] An array of solar cells converts solar energy into a usable amount
of direct current
(DC) electricity. Individual solar cell devices can be combined to form
modules, otherwise
known as solar panels. In some cases, an inverter can convert DC current /
power from a panel
into alternating current (AC).
[0018] The Applicants have realized that conventional articles that include
a solar cell, are
typically manufactured in a multiple-step method. First, the article itself is
produced or
manufactured, such as from plastic. Second, the solar cell or solar panel is
produced, separately
and by itself; often in an entirely different location or facility; and is
transported to the location
or facility where the article is produced. Third, the solar cell or solar
panel is connected or
glued or attached to the article; for example, using glue, or using screws, or
using other
mechanical connection mechanism, often via manual labor, and sometimes in an
automated or
semi-automated connection process.
[0019] The Applicants have realized that conventional articles having PV
energy
generation capabilities are conventionally produced by manufacturing a
finished or almost-
finished or nearly-finished or essentially-finished article, and then by
attached to it a solar cell
or a solar panel in a subsequent manufacturing process and via a mechanical
connection
process.
[0020] The Applicants have realized that such conventional production
methods and
production system, as well as the article that results from them, may have one
or more
disadvantages. For example, realized the Applicants, the step of mechanical
connection of the
solar panel to the almost-finished article, may be labor intensive and/or time
consuming and/or
error prone. Additionally or alternatively, realized the Applicants, it may
require delicate
and/or precise manual labor, sometimes requiring manual gluing or manual
utilization of
screws and screwdrivers; and sometimes causing inadvertent breaking or
cracking or damage
to the solar cell and/or to the article itself due to such step of mechanical
connection.
Additionally or alternatively, realized the Applicants, the mechanical
connection may be non-
resilient to shocks or forces that are subsequently applied to the article
(e.g., when the article
is transported, installed, and/or utilized); for example, a screw-based
connector may fail or may
become loose or open; a glue-based connection may fall apart or may weaken due
to
environmental heat; or the like. Additionally or alternatively, realized the
Applicants, the
mechanical connection sometimes causes the final article to have visible
and/or structural gaps
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or air-gaps that may be undesired; for example, the solar cell or solar panel
is sometimes
attached to the article via screws, in a manner that is not entirely tight
and/or secure and/or
hermetic, which allows water or liquids to flow through thin gaps that may
remain between the
solar cell and an adjacent region of the article; and possibly allowing such
water or liquid to
damage interior component(s) of the finished article. The applicants have also
realized that
conventional production methods of various plastic products or plastic-based
products, do not
allow for efficient manufacturing of an article having incorporated therein or
having embedded
therein a PV device or a solar cell at a curved region of the article or at a
non-planar or non-
flat region of the article.
[0021] The Applicants have realized that there is a need to embed,
connected, integrate
and/or incorporate a solar cell or a solar panel or other PV device or PV-
based electricity
generating unit, into an article of manufacture, in a manner that is more
efficient, more secure,
less prone to attachment mistakes or attachment problems, less labor
consuming, and more or
fully automated manner; as well as a need for producing a finished article
(having such solar
cell) which is more resilient to mechanical shocks and forces, and/or is more
leak-proof or
water-proof or liquid-proof, and/or has a secure and tight and integral
connection to a
surrounding or adjacent or neighboring region or part of the article itself.
[0022] Some embodiments provide methods and systems for producing an
article, and
particularly an article formed exclusive of plastic or formed dominantly from
plastic, by
performing one or more injection molding and/or blow molding and/or rotational
molding
process(es) such that the solar cell or solar panel or other PV device is
inserted or added or
placed as an "insert" item, before or during such molding process, and becomes
integrally
integrated or embedded or incorporated in the article during the molding
process; without a
subsequent need to perform a gluing step or a screwing of screws step or other
mechanical
connection step; and such that the molding itself, upon cooling down of the
article, causes the
solar panel or PV device to be integrally embedded and/or connected and/or
attached and/or
held in place within or on the finished article.
[0023] Some embodiments provide methods and systems for performing
injection molding
and/or blow molding and/or rotational molding process(es), utilizing and
incorporating in the
molded process a PV device or solar panel or solar cell.
[0024] In some embodiments, the PV device or solar cell or solar panel is a
rigid and non-
flexible; or, is flexible; or, is semi-rigid and/or semi-flexible, or is
partially-rigid and/or
partially-flexible; or, has an increased resilience to mechanical shocks and
forces, and/or has
an increased capability to absorb and/or dissipate mechanical shocks and
forces.
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[0025] In some embodiments, the PV device or solar cell or solar panel is
planar, or is flat,
or is a flat surface; in other embodiments, it is non-planar, or is curved or
concave or convex,
or has a three-dimensional structure other than a flat surface, or is
structured to have one or
more planar regions and one or more non-planar regions.
[0026] In some embodiments, particularly when non-flat or non-planar
structures or
contours are used, the PV device or solar cell is flexible or semi-flexible,
in order to increase
the ability of the PV device or solar cell to endure the stress(es) which may
be encountered
during the molding process, and/or to allow the PV device or solar cell to
modularly adapt to a
non-flat or non-planar region of the mold or the molding system.
[0027] In some embodiments, the manufacturing process may include attaching
one or
more PV devices to a surface of a mold; or placing, or mounting, or holding in
place, such one
or more PV devices onto a surface of a mold; or otherwise inserting one or
more PV devices
into a molding system or molding machine such that the PV device(s) are
positioned in a
manner and/or at a location that allows the molding process to be performed
while such PV
device(s) are within the machine or system. Then, the method includes
performing injection
molding or blow molding or rotational molding, of one or more polymer
material(s) and/or
plastic material(s) over the placed PV device(s); such that the molten polymer
or the molten
plastic attaches to (and/or surrounds) the pre-placed PV device(s), and such
that the molded
article and the PV device(s) become integral parts of the same, single,
finished article.
[0028] In some embodiments, the molten polymer or the molten plastic is
routed during
the process through particular routing paths within the molding machine or
systems, and/or
through the mold itself and/or by using particular and pre-configured cavities
for passage (or
for blocking) molten plastic or molten polymer, to ensure that the molten
plastic or molten
polymer would surround the PV device(s), or would create a border or frame
around the PV
devices; yet would not cover or would not obstruct the active surface (the
"sunny side") of the
PV device that is configured to absorb light.
[0029] In other embodiments, the PV device may be entirely encapsulated and
entirely
surrounded, from all 360 degrees around it, by molten plastic and/or molten
polymer, as such
molten polymer or molten plastic (or, the plastic or polymer after it cools
down and hardens)
are transparent and/or translucent and/or allow passage of light or sunlight
therethrough,
thereby maintaining the PV capability of the PV device even though it is
partially or entirely
surrounded or encapsulated by such plastic or polymer.
[0030] In some embodiments, a plurality of such PV device(s) are
electrically connected
to each other, in parallel and/or in series and/or via a particular electrical
circuit structure, to
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aggregate or accumulate or collect or build-up electric current and/or
electric voltage. In some
embodiments, two or more such PV devices are pre-connected to each other,
electrically, prior
to their placement as an "insert" in the molding places; and they remain
electrically connected
through and after the molding process. In other embodiments, two or more such
PV devices
are not electrically pre-connected to each other, prior to their placement as
an "insert" in the
molding places; but rather, they are placed as two or more separate "insert"
items; and only
after the molding process is performed, and optionally after cooling down of
the molded article,
the two or more PV devices are electrically connected to each other, e.g., via
wires, cables,
conductors, electrodes, or the like; which may be soldered or glued or bonded
to conducting
points or conducting regions or to electrodes of such PV devices).
[0031] In some embodiments, the single PV device that is inserted, or at
least one of a
series or a set or an array or an arrangement of such multiple PV devices, end
or terminate with
at least one set or one pair of terminals or electrodes, enabling to connect
the PV device(s) to
an external device (e.g., an external device that consumes and/or stores the
PV-generated
electricity). For example, the molded article may be a plastic box or a
plastic container, or a
plastic shack or shed or toolshed; and the PV device may be a set or array or
matrix or series
or solar panels that are integrally embedded or incorporated in a roof or
ceiling or wall or panel
of such box or container or shack or shed or toolshed; and the PV-generated
electricity that is
generated by such PV device is transferred via electrodes or wires or cables
to a rechargeable
battery or a rechargeable power cell that is located within the article or
nearby, or is transferred
to an appliance or device that consumes such PV-generated electricity or that
transports it
further to another electricity consuming device or electricity storage device.
[0032] In some embodiments, the manufacturing process and/or system may
optionally
utilize or include one or more steps or units or techniques that are sometimes
used in In-Mold
Labelling (IML) processes or systems; in which a label (e.g., paper label,
thin plastic label) is
utilized as an insert in the molding process.
[0033] In some embodiments, the one or more PV devices are manually and/or
mechanically placed or mounted or held in the mold or within the mold or
adjacent to the mold;
and are optionally held in place (e.g., temporarily, prior to and/or during
the molding process
itself) by vacuum, and/or by adhesive or glue, and/or by mechanical anchoring,
and/or via some
other connection method or mounting method or placement method or holding
method prior to
introducing the molten polymer or the molten plastic to the mold.
[0034] In some embodiments, the molding may be performed using a suitable
plastic
material or polymer; for example, a low-density polymer, a high-density
polymer,
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polyethylene, polypropylene, Acrylonitrile Butadiene Styrene (ABS), other
suitable
thermoplastic polymer(s) nylon, polystyrene, polyurethane, and/or other
polymers which may
be used in injection molding and/or blow molding and/or rotational molding
processes.
[0035] In some embodiments, the injection molding that is used may be, for
example,
screw injection molding, ram injection molding, reaction injection molding,
[0036] In some embodiments, the injection molding that is used may be, for
example,
screw-based or ram-based injection molding, e.g., that uses a screw or a ram
or other
component as a plunger to push or to force the molten polymer or the molten
plastic into the
mold cavity). For demonstrative purposes, some portions of the discussion
herein may relate
to injection molding that is non-reactive; however, some embodiments may
comprise, or may
be utilized in conjunction with, reaction injection molding or reactive
injection molding,
particularly utilizing polyurethane, as described herein.
[0037] In some embodiments, the injection molding that is used may be, for
example, a
Reaction Injection Molding (RIM) process or a Reinforced RIM process (e.g.,
using also one
or more reinforcement materials) or a Structural RIM process (e.g., using a
fiber mesh that is
placed or arranged within the mold); for example, utilizing low-viscosity
liquid polymer(s)
(e.g., polyol and isocyanate) that expand and/or thicken via chemical
reactions and harden after
their injection into a heated mold, resulting in a thermosetting article. In
some embodiments,
PU-RIM may be used, for example, a RIM process utilizing polyurethane as one
component,
and using a second component which may be (for example) one or more of the
following:
polyol, surfactant, catalyst, blowing agent, wetting agent, emulsifier,
foaming agent,
dispersants, and/or other components or a blend thereof or a mixture thereof.
In some
embodiments, the RIM may utilize polyureas, polyisocyanurates, polyesters,
polyphenols,
polyepoxides, Nylon 6, and/or other suitable materials.
[0038] In some embodiments, optionally, the polymer may include one or more
foaming
agents or foaming materials or foam-creating agents or foam-inducing agents or
blowing
agents, or chemical blowing agents (e.g., isocyanate; or isocyanate and water;
or
azodicarbonamide; or hydrazine or nitrogen-based materials; or sodium
bicarbonate); for
example, in order to reduce the density of the finished article, and/or to
reduce or absorb or
dissipate mechanical stresses or shocks or forces in the molded article,
and/or to assist in
creating a lightweight article, or for other purposes.
[0039] In some embodiments, the PV device(s) are placed or held or mounted
on, or at, or
adjacent to, a planar or flat area or region of the mold. Additionally or
alternatively, in some
embodiments, the PV device(s) are placed or held or mounted on, or at, or
adjacent to, a non-
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planar or non-flat or curved or contoured or convex or concave area or region
of the mold. In
some embodiments, one or more PV devices are placed or held on (or at) a
planar or flat region
of the mold; and also, one or more other PV devices are placed or held on (or
at) a non-planar
or non-flat or curved region of the same mold.
[0040] In some embodiments, a solar cell or a solar panel or a PV device
has two surfaces
or two sides: (A) a first surface or a first side, which is denoted as a
"sunny surface" or "sunny
side", or as "light-absorbing surface" or as "light absorbing side", or as
"light-facing surface"
or "light-facing side"; which is the side or the surface that is intended to
be facing sunlight or
the sun or a light source, or which is the side or the surface that is
configured to absorb sunlight
or light and to convert such absorbed light into electric charge(s) or
electricity or electric
current or electric voltage; and also, (B) a second surface or a second side,
which is denoted as
a "non-sunny surface" or "non-sunny side", or as a "dark surface" or "dark
side", or as "non
light-absorbing surface" or as "non light-absorbing side", or as "non light-
facing surface" or
"non light-facing side"; which is the side or the surface that is intended not
to be facing sunlight
or the sun or a light source, or which is opposite to and/or directed away
from the "sunny side",
or which is the side or the surface that is not configured to absorb sunlight
or light for
conversion into electric charge(s) or electricity or electric current or
electric voltage. In some
embodiments, a solar cell or a solar panel or a PV device is thus uni-facial
or is single-facial or
is one-sided, such that it can absorb light and convert it to electricity only
via its "sunny side"
and not via its "dark side".
[0041] In other embodiments, a solar cell or a solar panel or a PV device
has two surfaces
or two sides; wherein each one of them is, or can be seen as, or is configured
to be operable as,
a "sunny side" or a "sunny surface", facing away from each other towards
opposite directions;
such that the solar cell or solar panel or PV device is a bi-facial or double-
facial or dual-facial,
or is double-sided or double-facial, such that it can absorb and/or transfer
light and convert it
to electricity via each one of its two opposite surfaces or two opposite
sides. Such double-
sided PV device may be suitable for situations in which sunlight or light is
expected or intended
to reach the PV device from two or more directions, or from a direction that
is not perpendicular
to one of the surfaces of the PV device; for example, in a PV device that is
intended to be
installed generally perpendicular to the ground and may thus absorb sunlight
or light from both
of its sides at different times of the day, or in a PV device that is intended
to be moving or
rotating or spinning or otherwise changing its spatial orientation due to
movement or due to
other reasons.
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[0042] In some embodiments, the PV device is placed or mounted or held such
that its
"sunny side" (the active solar material that absorbs the light and converts it
to electricity) is
facing the mold or is facing towards the mold. In other embodiments, the PV
device is placed
or mounted or held such that its "sunny side" (the active solar material that
absorbs the light
and converts it to electricity) is facing away from the mold.
[0043] In some embodiments, the PV device is placed or mounted or held such
that its
"dark side" (the non-active side) is facing the mold or is facing towards the
mold. In other
embodiments, the PV device is placed or mounted or held such that its "dark
side" (the non-
active side) is facing away from the mold.
[0044] In some embodiments, a dual-sided or double-sided PV device may be
used, such
that one "sunny side" thereof is facing the mold, and another "sunny side"
thereof is facing
away from the mold.
[0045] In some embodiments, the molten polymer(s) or the molten plastic(s)
are
transparent and/or translucent and/or allow at least partial passage there-
through of light or
sunlight. Additionally or alternatively, the hardened or solidified
polymer(s), or the hardened
or solidified plastic(s), are transparent and/or translucent and/or allow at
least partial passage
there-through of light or sunlight. This may allow, for example, partial or
even complete
encapsulation of the PV device by molten plastic and/or molten polymer(s),
which then cool
down and/or harden and/or solidify into transparent or semi-transparent or
partially-transparent
or translucent layer(s) of plastic or polymer; and thereby providing a
finished article in which
the solar cell or the PV device is tightly and securely held in place, or is
even "buried" within
the finished article (e.g., for increased protection against mechanical
shocks), yet the PV device
is operational and operable since the transparent or translucent plastic
allows passage of light
there-through and the light reaches the active side(s) or the "sunny side(s)"
of the PV device
which generate electricity.
[0046] In some embodiments, optionally, the PV device is pre-encapsulated
between or
within one or more layers of polymeric films or coatings; for example,
Ethylene
Tetrafluoroethylene (ETFE) film(s) or coating(s) or layer(s), fluorine-based
plastic film(s) or
coating(s) or layer(s), fluoropolymer film(s) or coating(s) or layer(s),
Polyvinylidene Fluoride
(PVDF) film(s) or coating(s) or layer(s), thermoplastic fluoropolymer film(s)
or coating(s) or
layer(s), Thermoplastic Olefin (TPO) film(s) or coating(s) or layer(s),
Polyethylene (POE)
film(s) or coating(s) or layer(s), Ethylene Vinyl Acetate (EVA) film(s) or
coating(s) or layer(s),
or a combination of two or more of the above.
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[0047] In some embodiments, the molded article may be, for example, a box
or container,
a cooler box or cooler container (e.g., for camping) or ice chest or drinks
cooler box or picnic
box, or a storage unit, or a mobile home, or a shed or shack or toolshed or
storage shed; and
the PV device(s) may be an integrated part of a wall, a panel, a window, a
door, a roof, a ceiling,
or other component or region of such article.
[0048] In some embodiments, the molded article may be, for example, a roof,
or a shingle,
or a roof segment, or a roof cover, or a structure that is intended to cover
another object (e.g.,
to cover a vehicle, or to cover a parking spot or a parking lot), or a
pergola, or a shade structure;
and the PV device(s) may be an integrated part of such article.
[0049] In some embodiments, the molded article having the PV device
integrated therein
may be, for example, a plastic article that is intended to cover or to
protect, entirely or partially,
or to be mounted on, a vehicle, a car, a truck, a bus, a train, a train car or
train wagon, a
motorcycle, a boat, a yacht, a drone, an airplane, a self-driving vehicle, a
bicycle, an electric
bicycle, or a transportation device; and the PV device(s) may be an integrated
part of such
article; and the article may be molded based on, or to accommodate, the three-
dimensional
contour or structure or shape of such object that is intended to be covered or
protected; or, the
article may be molded according to the contour of such existing object or
vehicle (or its roof,
trunk, hood, or other region) and may be placed on top of (or may be attached
to) such object
or vehicle or roof.
[0050] In some embodiments, the molded article having the PV device
integrated therein
may be, for example, a vehicular plastic article; for example, a bumper, a
rear-side bumper, a
front-side bumper, a plastic roof-top mounting unit (e.g., for connecting
bicycles or items on
top of a vehicle), a back-side mounting unit (e.g., for connecting bicycles or
items behind a
vehicle), a vehicular roof or roof-segment (e.g., particularly when portions
of the roof are
formed of plastic materials, such as a roof of a convertible car), or the
like.
[0051] In some embodiments, the molded article having the PV device
integrated therein
may be, for example, an electronic device, an Internet of Things (IoT) device
or sensor, an
Internet-connected device, a home appliance, an electronic device capable of
wireless
communication and/or cellular communication, a smartphone, a housing for a
smartphone, a
tablet, a housing for a tablet, a smart-watch, a housing for a smart-watch, a
laptop computer, a
housing for a laptop computer, a desktop computer, a housing for a desktop
computer, a
security camera or an Internet-connected camera, a housing for a security
camera or for an
Internet-connected camera, or the like.
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[0052] In some embodiments, the molded article having the PV device
integrated therein
may be structured and/or configured to have a sufficiently-low density to
enable the article to
float on water; thereby enabling to produce, for example, a floating object, a
raft, a floating
walkway installed between islands or regions of floating solar panels, or
other floating
structures.
[0053] In some embodiments, optionally, the molded article is structured or
produced or
shaped such that the PV device(s) are placed in one or more recessed areas or
recessed regions
of the article, or in inwardly-facing craters or valleys. In some embodiments,
the boundaries
between or among such recessed areas or craters, may be sufficiently high
and/or may be
sufficiently close to each other, to allow a person to walk upon the article
or to allow a vehicle
to drive upon the article, with no contact or with minimal (and/or temporary)
contact between
the person's foot (or the vehicle's tires) with the PV device(s), thereby
preventing or
minimizing damage to such PV devices, and thereby enabling the PV-based
generation of
electricity within a sidewalk, a road, a bridge, or other structure.
[0054] The terms "PV device" or "PV unit" or "PV module" or "solar cell" or
"solar panel"
may be used interchangeably.
[0055] In accordance with some embodiments, the molded article and the PV
device(s) that
are integrally embedded therein are a single, monolithic, article. For
example, the PV device(s)
cannot be removed or un-screwed or un-glued or detached from the molded
plastic that
surrounds them and that holds them, without damaging the PV device(s)
themselves and/or the
surrounding molded plastic, and/or without deforming or cracking at least a
portion of the
surrounding molded plastic. The term "monolithic" as used above and/or herein,
particularly
with reference to the final article or the molded article, indicates (for
example) that it is a single
article, a singular article, an entire article, an article that is not
composed of two or more
detachable components; an article whose components cannot be efficiently (or
at all) un-glued
or un-bonded or un-screwed from each other; an article in which the PV device
is directly
attached to molded plastic(s) or molded polymer(s) via the molding itself or
via the molded
result itself, or via a molded solidified seamless connection that is formed
by the molten plastic
material(s) or polymer material(s) surrounding and/or encapsulating and/or
engulfing the PV
device from at least some of its sides or panels; or an article that is
uniform and singular such
that the PV devices is integrally and uniformly integrated within or embedded
within or
incorporated within the solidified previously-molten or previously-melted
plastic and/or
polymer; or an article in which the PV device is non-detachably attached to
its immediate
and/or surrounding and/or adjacent regions that are formed of molded plastic
and/or polymer;
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or an article in which there is absolutely no gap or no air gap or no space
between the PV device
and the molded plastic regions of the article that are immediately bordering
the PV device; or
an article that is not assembled from two discrete components (a plastic body,
and a PV device)
that are mechanically glued or screwed together, but rather, the PV device is
held in place via
its direct contact with the molded plastic(s) and/or polymer(s) that
solidified and hardened
immediately adjacent to it. In accordance with some embodiments, that does not
exist an
already-prepared "molded plastic body", to which a PV device is later screwed
or glued; but
rather, the molded plastic body is created simultaneously with, or
concurrently with, or at the
same time with, and/or via the same single operation of, molding the raw
plastic material(s) or
the raw polymeric material(s) to create, at the same time, the molded article
and the molded
"connection" that integrally connects the PV device to is concurrently-
solidified surrounding
plastic or polymer.
[0056] Reference is made to Fig. 1, which is a flow-chart of a method of
producing via
injection molding a plastic or polymeric article having integrated PV
device(s), in accordance
with some embodiments. In accordance with some embodiments, innovatively,
surprisingly,
and counter-intuitively, a fully operable PV device, which is an Actively
Functional electric
device that generates electric power from absorbed light, is incorporated or
embedded in the
mold and/or the molding process and/or the molding machine; and surprisingly,
and counter-
intuitively, the PV device remains operable and/or operational and/or
functional, even though
it may be exposed to or may be subject to heat and/or high temperature and/or
pressure during
the molding process; and the PV device, in its post-molding state, remains
operational and
functional, either in its entire capacity as it was prior to the molding
process, or at least in a
partial capacity that is still useful and sufficient for the particular
purpose(s) of that PV device
and/or that molded article (or another device that consumes or that stores the
PV-generated
electric energy).
[0057] As indicate in block 101, one or more Solar Cell(s) or PV Device(s)
are attached to,
or mounted or placed adjacent to, an inside region of a Mold of an injection
molding machine
or system; for example, by double sided adhesive, temporary adhesive, vacuum,
mechanical
anchor, holding pin(s), other means.
[0058] As indicated in block 102, the Mold is closed.
[0059] As indicated in block 103, hot molten plastic material(s) and/or hot
molten
polymer(s) are injected.
[0060] As indicated in block 104, the Mold is then cooled down; and the
molded article
hardens and/or solidifies.
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[0061] As indicated in block 105, the method includes removing or ejecting
the injection-
molded article having the integrated Solar Cell(s) / PV Device(s). For
example, the Solar
Cell(s) / PV Device(s) are integrally incorporated in, or on, or as part of, a
particular region of
an external layer or external side of the injection molded article.
[0062] Reference is made to Fig. 2, which is a flow-chart of a method of
producing via
blow molding a plastic or polymeric article (e.g., a hollow or partially-
hollow plastic or
polymeric article) having integrated PV device(s), in accordance with some
embodiments. In
accordance with some embodiments, innovatively, surprisingly, and counter-
intuitively, a fully
operable PV device, which is an Actively Functional electric device that
generates electric
power from absorbed light, is incorporated or embedded in the mold and/or the
molding process
and/or the molding machine; and surprisingly, and counter-intuitively, the PV
device remains
operable and/or operational and/or functional, even though it may be exposed
to or may be
subject to heat and/or high temperature and/or pressure during the molding
process; and the
PV device, in its post-molding state, remains operational and functional,
either in its entire
capacity as it was prior to the molding process, or at least in a partial
capacity that is still useful
and sufficient for the particular purpose(s) of that PV device and/or that
molded article (or
another device that consumes or that stores the PV-generated electric energy).
[0063] As indicate in block 201, one or more Solar Cell(s) or PV Device(s)
are attached to,
or mounted or placed adjacent to, an inside region of a Mold of a blow molding
machine or
system; for example, by double sided adhesive, temporary adhesive, vacuum,
mechanical
anchor, holding pin(s), other means.
[0064] As indicated in block 202, a parison is formed of plastic
material(s) and/or
polymeric material(s). For example, the parison is a tube-like piece of
plastic with a hole in
one end, through which compressed air can pass and enter the parison and
remain trapped in
the parison.
[0065] As indicated in block 203, the parison is introduced or inserted
into the mold, or (in
some embodiments) may be clamped within the mold.
[0066] As indicated in block 204, the method includes blowing or inflating
the parison; for
example, using air and/or hot air and/or compressed air and/or pressurized
air. The air pressure
pushes the plastic or polymers outwardly, inflating the parison to match the
structure and shape
of the mold that surrounds it.
[0067] As indicated in block 205, the mold is cooled down, the blow molded
article hardens
and solidifies, and the mold is opened to allow removal of the blow molded
article therefrom.
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[0068] As indicated in block 206, the method includes removing or ejecting
the blow-
molded article having the integrated Solar Cell(s) / PV Device(s). For
example, the Solar
Cell(s) / PV Device(s) are integrally incorporated in, or on, or as part of, a
particular region of
an external layer or external side of the blow molded article.
[0069] Reference is made to Fig. 3, which is a flow-chart of a method of
producing via
rotational molding a plastic or polymeric article (e.g., a hollow or partially-
hollow plastic or
polymeric article) having integrated PV device(s), in accordance with some
embodiments. In
accordance with some embodiments, innovatively, surprisingly, and counter-
intuitively, a fully
operable PV device, which is an Actively Functional electric device that
generates electric
power from absorbed light, is incorporated or embedded in the mold and/or the
molding process
and/or the molding machine; and surprisingly, and counter-intuitively, the PV
device remains
operable and/or operational and/or functional, even though it may be exposed
to or may be
subject to heat and/or high temperature and/or pressure during the molding
process; and the
PV device, in its post-molding state, remains operational and functional,
either in its entire
capacity as it was prior to the molding process, or at least in a partial
capacity that is still useful
and sufficient for the particular purpose(s) of that PV device and/or that
molded article (or
another device that consumes or that stores the PV-generated electric energy.
[0070] As indicate in block 301, one or more Solar Cell(s) or PV Device(s)
are attached to,
or mounted or placed adjacent to, an inside region of a Mold of a rotational
molding machine
or system; for example, by double sided adhesive, temporary adhesive, vacuum,
mechanical
anchor, holding pin(s), other means.
[0071] As indicated in block 302, the mold is loaded with a "charge" or a
"shot" or a pre-
defined amount of raw plastic material(s) and/or raw polymeric material(s),
such as raw plastic
powder or raw plastic granules or raw plastic resin.
[0072] As indicated in block 303, the method includes heating and
continuously rotating
the Mold. The heat causes the raw plastic / polymeric materials to melt, and
the rotation causes
them to be pushed outwardly and coat the inner walls of the Mold.
[0073] As indicated in block 304, after a pre-defined time (e.g., five
minutes) and/or after
a pre-defined number of rotations, the method includes: stopping to heat the
Mold, or stopping
any heating of the Mold, or no longer providing any heat to the Mold; while
continuing to
rotate the Mold.
[0074] As indicated in block 305, after a pre-defined time (e.g., ten
additional minutes)
and/or after a pre-defined number of (additional) rotations, or when the
temperature of the mold
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reaches below a pre-defined threshold temperature value, the method includes:
the mold
sufficiently cools down, and the rotation of the mold is stopped; and then,
the Mold is opened.
[0075] As indicated in block 306, the method includes: removing or ejecting
the rotational
molded article having the integrated Solar Cell(s) / PV Device(s). For
example, the Solar
Cell(s) / PV Device(s) are integrally incorporated in, or on, or as part of, a
particular region of
an external layer or external side of the rotational molded article.
[0076] Reference is made to Figs. 4A to 4G, which are schematic
illustrations
demonstrating components and operational steps of an injection molding system
400, in
accordance with some demonstrative embodiments. In accordance with some
embodiments,
innovatively, surprisingly, and counter-intuitively, a fully operable PV
device, which is an
Actively Functional electric device that generates electric power from
absorbed light, is
incorporated or embedded in the mold and/or the molding process and/or the
molding machine;
and surprisingly, and counter-intuitively, the PV device remains operable
and/or operational
and/or functional, even though it may be exposed to or may be subject to heat
and/or high
temperature and/or pressure during the molding process; and the PV device, in
its post-molding
state, remains operational and functional, either in its entire capacity as it
was prior to the
molding process, or at least in a partial capacity that is still useful and
sufficient for the
particular purpose(s) of that PV device and/or that molded article (or another
device that
consumes or that stores the PV-generated electric energy.
[0077] In order to focus on some particular aspects of some embodiments,
and in order to
not obscure the drawings, conventional components of an injection molding
machine are not
shown, and can be used to achieve their respective functionality. For example,
an injection
molding machine may include an injection unit, which performs heating and
injecting of
molten material into a mold. The injection unit may include a hopper, which is
a container that
receives raw plastic material(s) or polymer(s); for example, as pellets, as
granules, as powder,
as blocks, as beads, as solid units, or the like. In some embodiments,
optionally, the pellets or
granules of raw plastic material(s) or polymer(s) may comprise one or more
reinforcement
elements or mechanical resilience elements or mechanical support elements or
mechanical
reinforcing agents, such as, glass fiber, chopped glass fiber, diced glass
fiber, fibers of glass,
chopped or cut fibers of glass, thin strands of glass or silica-based
formulations, E-glass fibers
or strands (e.g., formed of alumino-borosilicate glass, typically with less
than 1% w/w alkali
oxides), A-glass fibers or strands (e.g., Alkali-lime glass with no boron
oxide or with a
negligible amount thereof), E-CR-glass fiber or strands (e.g.,
Electrical/Chemical Resistance
glass fibers or strands; for example, alumino-lime silicate, typically with
less than 1% w/w
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alkali oxides, with high acid resistance), C-glass fibers or strands (e.g.,
alkali-lime glass with
high boron oxide content), D-glass fibers or strands (e.g., borosilicate
glass, having a low
Dielectric constant), R-glass fibers or strands (e.g., alumino silicate glass,
without MgO and
CaO, having high mechanical reinforcement properties), S-glass fibers or
strands (e.g., alumino
silicate glass, without CaO but with high MgO content, providing high tensile
strength), mica,
mica crystals, mica fibers or strands, crystallized phyllosilicate mineral(s),
and/or other suitable
reinforcement agents or materials.
[0078] A bottom opening of the hopper transfers, or feeds, the raw
material(s) into a barrel,
which includes the mechanism for heating and injecting the material into the
mold. A plunger
or a reciprocating screw or a rotating screw or a ram injector or other
suitable injection member
or extruder (e.g., using electric motor or hydraulic motor) moves or pushes or
advances the
material(s). A heating unit or multiple heaters surround (or are adjacent to)
the barrel-region
or the channel through which the material(s) advance, and provide to them
heat. The advancing
material(s) melt due to the heat, and optionally also due to pressure and
friction which
contribute to such melting. The molten material(s) are injected rapidly into
the mold, through
an injection nozzle and via a die or opening at the end of the barrel, using
an injection force
provided by the buildup of pressure and/or by the rotation of the rotating
screw and/or by the
push forces applied to the material(s). The injected materials fill a cavity
within the mold, that
is defined by particularly-structured gaps between a female member and a male
member of the
mold. After the injection, the molten material(s) cool-down, harden and
solidify within the
mold, resulting in an injection-molded article. Then, the mold may be opened,
and/or the
injection screw (or other injection mechanism) may be retracted; and the
injection-molded
article may be released or extracted or ejected or otherwise released from the
mold.
[0079] Prior to injection, the two members or two halves of the mold are
securely closed
by a clamping unit, each member affixed to a platen or a large plate. The
female member of
the mold may also be known as the member having the mold cavity, or as the
front member or
the front-side member. The male member of the mold may also be known as the
rear member
or the rear-side member, or as the mold core. The mold may be formed of steel
or aluminum
or other suitable metal(s). Optionally, multiple discrete cavities may be
defined by multiple
discrete gaps between the male member and the female member, and/or the three-
dimensional
structure or shape or contour of those members.
[0080] Typically, the female member is affixed to a stationary, non-moving,
front-side
platen that aligns with the nozzle of the injection unit (e.g., the alignment
may also be aided by
locating ring). Typically, the male member is mounted on or affixed to a
movable platen which
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may slide along tie bars or rails. Molten material(s) enter the mold cavity
via the nozzle and a
sprue, and move through one or more channels and/or gates and/or "runners"
(which may be
non-heated; or in some implementations, may be heated) which carry and/or
guide and/or route
the molten material(s).
[0081] The clamping unit may be equipped with a hydraulically powered
clamping motor,
to actuate clamping bars and/or clamping forces that keep the mold securely
closed during the
actual pressurized injection of molten material(s) into the mold cavity, as
well as during the
cooling-down period that follows the injection. After a pre-defined time
period (e.g., ten
minutes), the mold may be opened (e.g., by distancing the male member from the
female
member). An ejector bar or ejector pin or ejector plate or other ejection unit
may be actuated
to eject or release or remove or pull the solid injection-molded article from
out of the mold
cavity. Optionally, water-based cooling or other type of cooling may be used
to hasten the
cooling down; for example, by running water or cold water through cooling
channels that are
near or adjacent to the mold. Optionally, the mold cavity is pre-configured to
support or to
enable flow of the molten material(s) to all the regions of the cavity that
should be filled with
such material(s). Optionally, a draft angle may be applied to one or more mold
wall(s) or
panel(s), to facilitate ejection or removal of the solid article.
[0082] In Fig. 4A, there is shown a system 400 which comprises an injection
molding mold
having two members: a male member 401, and a generally complementing female
member
402. One or more injection port(s) 403 or other suitable injection channel(s)
or injection
pathway(s) or injection aperture(s) are in the female member 402, to enable
injection and entry
of molten polymer(s) or molten plastic material(s). A mold cavity 404 is
defined between the
male member 401 and the female member 402, based on their particular three-
dimensional
structure or shape or contour. The mold cavity 404 may have a single or a
unified or a
continuous cavity; or alternatively, a set of two or more discrete or separate
cavities.
[0083] As demonstrated in Fig. 4B, a PV device 444 is placed within the
mold cavity. For
example, it is placed at a particular location 443 in the mold cavity 404; for
example, adjacent
to (or mounted on, or adhered to, or glued to) the female member 402.
Optionally, a vacuum
port 406 or a vacuum channel, or a suction port or channel, may be used to
provide an
outwardly-directed force that pushes (via vacuum or suction forces) the PV
device 444 towards
an inside wall or an inside panel or an inside region of the female member
402. In Fig. 4B,
there is further shown a PV device 444 that is placed within the mold cavity.
[0084] Optionally, the PV device 444 may be temporarily held in place, on
an inner-side
wall or region of the female member, not necessarily using vacuum or suction
forces; but rather,
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using adhesive(s), double-sided adhesive, temporary or short-term adhesive; or
via magnetic
forces (e.g., the PV device 444 may be magnetic north, and the female member
may be
magnetic south; or vice versa); or using a mechanical anchor or anchoring
member or
anchoring pin; or using a small pin or clasp; or by fitting the PV device 444
into a particular
groove or crater or recess or recessed region in the female member that then
holds in place the
PV device 444 via friction and/or pressure.
[0085] In Fig. 4A and 4B, the mold is in an open position, such that the
two mold members
401-402 are spaced apart. In Fig. 4C, the mold is shown in a closed position,
such that at least
some of the internally-facing region of the male member 401, directly touches
at least some of
internally-facing region of the female member 402; while a cavity is still
defined between the
two mold members 401-402 that now touch each other, upon closure of the mold
and prior to
injection of molten material(s).
[0086] Fig. 4D shows the system, with the molten material(s) 408 flowing
into, and filling,
the mold cavity of the closed mold. The molten material(s) 408 may touch the
PV device 444,
or may partially cover it, or may even entirely cover or encapsulate it (e.g.,
if transparent and/or
translucent material(s) are used, to still allow at least partial passage of
light towards the active
parts or to a "sunny side" of the PV device 444).
[0087] Fig. 4E shows the system after the mold cooled-down, and after the
male member
401 was retracted or distanced from the female member 402, thereby opening the
mold cavity.
A solid, monolithic, injection-molded article 455 was created, integrally
incorporating therein
the PV device 444 as an integral part thereof. The PV device 444 is injection-
mold connected
to the other regions of the injection-molded article 455. Fig. 4F shows an
enlarged view of
the injection-molded article 455 as a stand-alone article, after its ejection
or removal or release
from the female member 402 of the mold.
[0088] Fig. 4G shows schematically some of the above-mentioned units of
system 400; for
example, hopper 421 which holds raw plastic / polymeric material(s), barrel
422, screw 423,
heater(s) 424, injection nozzle and die 425.
[0089] It is noted that the drawings are not necessarily drawn to scale;
rather, the size of
some components is intentionally exaggerated, in order to show more clearly
some particular
features, structures, or functionalities. For example, in some embodiments,
the length or the
longest dimensions of PV device 444 may range from 1 centimeter to 100
centimeters; whereas
the injection molding system is typically a machine having a length in the
range of 2 to 8
meters, although smaller injection molding systems or machines may be used
(e.g., "lab scale"
machines, having a length of 50 or 100 centimeters).
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[0090] In some embodiments, blow molding or Extrusion Blow Molding (EBM)
may be
used, instead of injection molding. For example, raw plastic material or raw
polymeric material
is melted and extruded into a hollow tube, called a parison. The parison is
then captured by
closing it into a cooled metal mold. Air is blown into the parison, inflating
it into the three-
dimensional shape as defined by the metal mold. After the plastic has cooled
sufficiently, the
mold is opened and the formed article is ejected or removed or released. Some
embodiments
may utilize one or more processes such as, for example, straight EBM; or EBM
with an
Accumulator; or Continuous EBM; or Intermittent EBM; optionally also
performing Spin
Trimming. Some embodiments may perform injection blow molding (IBM), in which
the
polymer is injection-molded onto a core pin; then the core pin is rotated to a
blow molding
station to be inflated and cooled. Some embodiments may perform injection
stretch blow
molding, which may be a single-stage process or a double-stage process.
[0091] In some embodiments, Rotational Molding or Roto-Molding may be used,
instead
of injection molding. For example, it is a plastic casting technique that
enables to produce a
hollow or partially-hollow plastic or polymeric article. It uses a hollow
mold; for example,
thermoplastic powdered resin is heated while being rotated, and is then cooled
to harden and
solidify.
[0092] In some embodiments, the Rotational Molding does not require any
injection or
pressure; and may thus enable to use inexpensive machines, and may be used to
produce very
large articles (e.g., having a longest dimension that is larger than 1 meter,
or larger than 2
meters).
[0093] In some embodiments, the Rotational Molding utilizes an arm or
cradle, which
carries the mold; single or multiple ovens; and cooling chambers.
[0094] In some embodiments, the Rotational Molding utilizes a Clamshell
Machine: it is a
single station machine, wherein molding and cooling occurs in one chamber. The
mold with
resin is loaded and unloaded in the chamber through a front panel. The front
panel and cover
are locked during heating and molding. After molding, the cover is opened to
allow cooling,
causing the mold to be swung out of the open oven.
[0095] In some embodiments, the Rotational Molding utilizes a Turret or
Carousel
Machine, which rotates at a center pivot and has three to six arms. Each arm
has a mold attached
to its end and passes through stations in the order of the rotational molding
process, from
loading, heating, cooling, and unloading, throughout the rotation of the
carousel.
[0096] In some embodiments, the Rotational Molding utilizes a Shuttle
Machine, which
has independent arms that rotate biaxially and move the mold from loading,
cooling, and
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unloading (combined stations) to the heating chamber located at the middle of
the track. The
mold returns to its original position after the process is completed.
[0097] In some embodiments, the Rotational Molding utilizes a Swing
Machine, which
similarly has independent arms (e.g., up to four arms); but it is not needed
to operate all arms,
thereby increasing production efficiency. The arms mounted at the corner of
the oven rotate
biaxially and swing the mold from the heating to the cooling chamber.
[0098] In some embodiments, the Rotational Molding utilizes a Vertical
Wheel Machine,
which operate like a Fen-is wheel. The molds are contained in a cradle and are
moved from
loading / unloading, heating, and cooling throughout its rotation. The loading
/ unloading
station is located at the bottom of the wheel, in between the cooling and
heating areas.
[0099] In some embodiments, the Rotational Molding utilizes a "Rock and
Roll" machine,
which has molds contained in a cradle. The cradle swings 45 degrees back and
forth on a
horizontal axis, 45 degrees or below the horizontal axis while rotating 360
degrees on a
perpendicular axis. Rock and Roll machines may be particularly suitable for
producing an
elongated article that floats on water, such as a canoe or a kayak or a marine
vessel part.
[00100] The steps involved in a rotational molding operation may be as
follows.
[00101] (A) Loading: A measured quantity of the polymer, such as in powdered
resin form,
is placed in a hollow mold and secured tightly. The powdered resin is in fine
sizes,
homogeneous, and dried to achieve a good flow and prevent bubble formation.
The amount of
resin loaded is one of the factors which determine the wall thickness of the
article.
[00102] The hollow mold is made from cast aluminum or fabricated steel sheet
and gives
the molded part its shape.
[00103] A mold release agent is a coating present on the inner walls of the
mold. It is used
for effective removal or ejection of the molded article after cooling, as it
prevents sticking of
the molded article to the mold's inner surface.
[00104] Some types of mold release agents are, for example: (i) Sacrificial
coating, such as
silicone, which comes off with the molded article when it is released from the
mold; and hence
it is applied at the start of every loading process. (ii) Semi-permanent
coating or semi-
permanent mold release agent, which can last several cycles of heating and
cooling of the
polymer; it may be re-applied or topped up before being used up. (iii)
Permanent coating, such
as polytetrafluoroethylene (PTFE), which eliminates the need for re-
application of a mold
release agent, as it is permanently fixed on the inner mold surface; however,
the permanent
mold release agent layer may wear off due to scratching or mishandling.
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[00105] (B) Heating and Rotating: The powdered resin is heated inside the
hollow mold
while being rotated slowly until all the resin is melted. As the resin melts,
it coats the entire
inner wall of the mold. The simultaneous action of heating and rotating
ensures uniform
distribution of the resin inside the mold. The mold rotates biaxially and
usually at a slow speed,
such as, less than 15 rotations per minute (RPM).
[00106] In some embodiments, to achieve suitable wall thickness distribution,
a proper
rotation ratio is determined and utilized. This value is the number of RPM on
the horizontal
axis over RPM on the vertical axis. For example, an article that would be
generally a sphere or
a cube can be molded at a rotation ratio of 4:1. For irregular shaped solids
or elongated solids,
the ratio may be 1:8 or 8:1, or other suitable ratio.
[00107] The heating time of the polymer is pre-defined, and is one of the
parameters which
determines the quality of the finished article. For example, excessive heating
time may result
in thermal degradation of the polymer and/or may degrade the mechanical
properties of the
final article, such as reduced resistance to wear and impact. In contrast,
insufficient heating
time would result in incomplete melting of the polymer; unmolten grains will
not coalesce with
the molten resin, which results in bubble formation; and such variation may
have adverse
effects on the mechanical properties of the article.
[00108] (C) Cooling: In the cooling stage, the molten polymer inside the mold
hardens and
solidifies into its desired shape. The outside of the rotational mold is
cooled by natural or forced
convection, usually using air or cold air. Optionally, cooling air may be
supplied to the mold
internals to maintain dimensional stability during cooling. Water sprays may
be used to reduce
the cooling time, although this may affect the mechanical properties and/or
dimensions of the
article.
[00109] In some embodiments, the cooling time of the polymer is as important
as the heating
time. Thus, the proper cooling rate may be determined and utilized. Cooling
too rapidly may
result in uncontrollable warpage and shrinkage of the article; whereas slow
cooling may cause
a flow of the molten resin, resulting in inconsistent wall thickness.
[00110] (D) Demolding or Unloading: The cooled article is removed, by a human
operator
or by a robotic arm or removal unit, from the hollow mold. Optionally, an air
ejection unit may
assist in lifting the article out of the mold.
[00111] In some embodiments, Rotational Molding may utilize polymers that are
thermoplastics. Some embodiments may utilize Polyethylene, due to its low cost
and/or ease
of molding; it is readily available in powdered form, unlike non-polyethylene
polymers which
may be more difficult to grind; and It also has good chemical resistance and
low water
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absorption. Some embodiments may utilize Polyethylene grades such as, for
example, High-
Density Polyethylene (HDPE), Low Density Polyethylene (LDPE), Medium Density
Polyethylene (MDPE), and Linear Low-Density Polyethylene (LLDPE).
[00112] Some embodiments may utilize Polypropylene, which is a versatile
polymer;
having characteristics between LDPE and HDPE; having properties of chemical
resistance,
heat resistance, and fatigue resistance.
[00113] Some embodiments may utilize Polyvinyl Chloride, which is the polymer
form of
vinyl chloride monomer; it is a strong and rigid plastic, and is compatible
with various additives
to modify its mechanical properties.
[00114] Some embodiments may utilize Nylon, which comes from the polyamide
plastic
group and may be used as a molding compound; it is generally tough, with
suitable thermal
and chemical resistance.
[00115] In some embodiments, the raw material may be selected for rotational
molding
based on one or more relevant considerations. For example, the molten plastic
will be exposed
to oxygen at high temperatures, which may result in oxidation and loss of the
desired
mechanical properties of the polymer; therefore, the molecule of the polymer
material should
have groups with antioxidant properties. As another consideration, the polymer
should have
high thermal stability for the material to resist permanent changes brought by
high
temperatures. As another consideration, the molten material should easily flow
within the walls
of the mold, since flow is dependent on rotational movement only and there is
no pressure
involved; and thus the flow characteristics of the chosen polymer at high
temperatures should
be considered.
[00116] In some embodiments, primary additives may be added and used to
improve the
mechanical properties of the article and/or to assist in the molding process.
Flow modifiers may
assist in the flow of polymer resin in the molten state to achieve proper and
uniform thickness
distribution. Heat stabilizers may be sed to prevent thermal degradation that
may be induced
by high temperature. Fillers may be used to increase the stiffness; and impact
modifiers may
be used to increase impact strength; however, the amount of such additive may
need to be
controlled since they may cause rough surface and/or reduced flow. Secondary
additives may
also be utilized to give the finished article its characteristics, such as
colorants, flame retardants,
and anti-static agents.
[00117] In accordance with some embodiments, the solar cell or the PV device,
that is
utilized as part of the injection molding process or the RIM process or the
rotational molding
process or the blow molding process, is a fully-prepared or fully-operational
or fully-produced
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or readily-functional or pre-manufactured solar cell or PV device, or a
freestanding or non-
supported or stand-alone or autonomous or a self-contained solar cell or PV
device, which is
an Active Functional Device or an Active Functional electric device that
directly generates
electricity from absorbed light, and that is electrically connected (e.g., via
wires, cables,
conductors, electrodes, electric circuit) to one or more electric energy
consuming units and/or
to one or more electric energy storing units.
[00118] The Applicants have discovered and realized that in accordance with
some
embodiments, a fully-operational or fully-operable, pre-manufactured or
already-prepared,
solar cell or PV device, surprisingly and counter-intuitively does not melt
and/or does not get
damaged and/or does not get ruined and/or does not become inoperable and/or
does not break
apart, when it is incorporated in an injection molding or RIM or rotational
molding or blow
molding process or machine or system or mold.
[00119] Surprisingly and counter-intuitively, discovered and realized the
Applicants, the
solar cell or PV device remains operational or operable, entirely or at least
partially, or at least
remains in an operational state that allows it to still produce sufficient
amount of electric current
and/or electric voltage and/or electric power in its post-molding state (e.g.,
generating and
providing sufficient electric power to a power-consuming unit or device or to
a power-storing
unit or device), even though such solar cell or PV device has been inserted
into a mold and/or
a molding machine, and/or even though such solar cell or PV device has been
subjected to heat
or high heat or high temperatures during the molding process, and/or even
though such solar
cell or PV device has been subjected to pressure or high pressure or clamping
pressure or other
mechanical forces during the molding process.
[00120] Innovatively, the Applicants have realized that nobody has attempted
to place a
fully-operational or fully-operable Actively Functional device, such as the
solar cell or the PV
device described above and/or herein, into a mold or into a molding machine,
or to embed or
incorporate such device in such high-heat and/or high-pressure molding
process. The
Applicants have realized that conventional production methods have, at best,
attempted to
perform "insert molding" processes in which a Passive Mechanical Device was
inserted or
used; for example, a passive metal Screw, or a passive metal Nail, or a
passive metal Cylinder.
[00121] In accordance with some embodiments, the solar cell or the PV device
that is
inserted, embedded, incorporated and/or other utilized in the molding process,
is formed of
semiconductor material(s) such as (for example) silicon, gallium arsenide,
cadmium telluride,
or other material(s). The fully-operable solar cell of PV device absorbs
sunlight; and due to the
PV effect, free electrons and holes are created at positive / negative
junctions; and such
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junctions are connected via electrodes or conductors or conducting circuits or
wires that collect
or aggregate electric charge and generate electric current and/or electric
voltage. The solar cell
or PV device may be, for example, a large-area or medium-area or small-area p-
n junction
made from silicon; a Crystalline Silicon or c-Si solar cell or PV device; a
Single Crystalline
Silicon or Monocrystalline silicon solar cell or PV device; a Polycrystalline
Silicon or multi-
crystalline silicon solar cell or PV device; an Amorphous Silicon or a-Si
solar cell or PV device,
or Thin-Film solar cell or PV device; a Hybrid Silicon PV solar cell or PV
device (e.g., having
a combination of single crystalline silicon surrounded by thin layers of
amorphous silicon),
and/or other suitable type of solar cell or PV device.
[00122] In some embodiments, for example, Mono-crystalline or Poly-crystalline
silicon
wafers are created; for example, by cutting or wire-sawing block-cast silicon
ingots into wafers
(e.g., each wafer having thickness in the range of 180 to 350 micrometer). In
some
embodiments, the wafers are lightly p-type-doped. A surface diffusion of n-
type dopants is
performed on a front side (the "sunny side") of the wafer; thereby forming a
p¨n junction,
typically located a few hundred nanometers below the surface.
[00123] Optionally, one or more anti-reflection coatings are applied, to
increase the amount
of light that is coupled into or absorbed by the solar cell. For example,
silicon nitride may be
used, or (in some implementations) titanium dioxide, due to their surface
passivation
properties, to prevent carrier recombination at the cell surface. For example,
a coating layer
(e.g., 200 to 800 nanometers thick) may be applied, using plasma-enhanced
chemical vapor
deposition. Optionally, the solar cell may have textured front surfaces or
three-dimensional
structures, that may increase the amount of light reaching the wafer.
[00124] In some embodiments, a full area metal contact is formed on the back
surface (the
"dark side"); and a grid-like metal contact, which includes fine "fingers" and
larger "bus bars",
may be screen-printed onto the front ("sunny side") surface using a silver
paste. In some
embodiments, rear side (or "dark side") contacts are formed by screen-printing
a metal paste,
such as aluminum; and such contact may cover the entire rear side, or may be a
grid pattern.
In some embodiments, metal paste is heated at several hundred degrees Celsius
to form metal
electrodes in ohmic contact with the silicon. Optionally, an additional
electroplating step may
be used, to increase efficiency. After the metal contacts are made, the solar
cells are
interconnected by flat wires and/or metal ribbons, and assembled into modules
or Solar Panels.
Typically, a solar panel has a sheet of tempered glass on the front (the
"sunny side" surface),
and a polymer encapsulation on the back (the "dark side" surface).
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[00125] In some embodiments, when light or sunlight strikes the solar cell (or
PV device)
surface, the solar cell creates charge carrier as electrons and holes. An
internal field produced
by junction separates some of positive charges (holes) from negative charges
(electrons). Holes
are swept into positive layer or p-layer; electrons are swept into negative
layer or n-layer.
Individual solar cells may be connected together (electrically) to thus create
a PV device or PV
module or Solar Module, to increase or aggregate electric current or electric
voltage; typically
by connecting individual solar cells in an array or Solar Array or PV array;
such as, solar arrays
may be connected in parallel and thus the output electric current is
increases, or solar arrays
may be connected in series and thus the output electric voltage is increased,
or via a different
type of array or circuit having one or more region(s) or solar cells that are
inter-connected in
parallel and/or having one or more region(s) that are inter-connected in
series.
[00126] In some embodiments, the PV device includes the Solar Cell or the
Solar Module,
which directly converts light into Direct Current (DC) electricity; and
optionally, it includes or
it is connected to a battery that is charged or recharged; optionally also
connected to a Solar
Charge Controller which regulates voltage and/or current from solar arrays,
and/or charges a
battery, and/or prevents a battery from overcharging, and/or performs
controlled over-
discharges; and optionally utilizing an Inverter to convert DC power output of
solar arrays into
AC power.
[00127] In some embodiments, optionally, the solar cell or PV device may be a
mechanically-resilient and/or flexible and/or rollable and/or bendable and/or
foldable solar cell
or PV device; for example, due to having non-transcending gaps or "blind gaps"
or craters that
penetrate into from 80 to 99.9 percent of the depth of the semiconductor
wafer; which provide
mechanical resilience, and/or enhanced ability to absorb and/or dissipate
mechanical forces
and/or mechanical shocks; including, but not limited to, structures and/or
components as
described in United States patent number US 11,081,606 B2, which is hereby
incorporated by
reference in its entirety.
[00128] In some embodiments, optionally, the solar cell or PV device may be
flexible,
and/or may already be curved and/or non-flat and/or non-planar, prior to
and/or during its
insertion into the mold or into the molding machine; or, may intentionally
become curved or
non-planar or non-flat due to its insertion and/or placement into the mold or
the molding
machine; thereby allowing to produce a molded article that integrally
incorporates therein or
thereon, via molding of molten plastic(s) and/or molten polymer(s), such
curved or non-planar
or non-flat solar cell or PV device.
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[00129] In some embodiments, the utilization of a solar cell or a PV device
that is
mechanically-resilient and/or flexible and/or rollable and/or bendable and/or
foldable, may
contribute to the ability of the solar cell or PV device to withstand and/or
to survive,
mechanically and/or thermally and/or physically and/or operably, the heat
and/or pressure that
are involved in the molding process; as some (or all) of such heat and/or
pressure and/or
mechanical forces of the molding process, may be absorbed and/or dissipated
and/or mitigated
by the particular three-dimensional structure of the solar cell or PV device,
and particularly by
the above-mentioned non-transcending craters or gaps or "blind gaps" that
penetrate into
between 80 to 99.9 percent of the depth or thickness (but not the entire 100
percent of the depth
of thickness) of the semiconductor substrate or wafer of the PV device; and
optionally, due to
filler material(s) which may fill (partially, or entirely) such non-
transcending gaps or craters
and which may absorb mechanical forces and/or chemical forces and/or physical
forces and/or
heat and/or pressure(s) and/or thermal shock and/or thermal changes.
[00130] Reference is made to Fig. 5A, which is an illustration of a prior art
hybrid non-
monolithic product 501; formed by gluing together two discrete and separate
objects: (i) a PV
device 502, and (ii) an already-molded plastic body 503. As shown, glue
connection(s) 510
are used, depicted by black regions; but they often leave one or more Gaps
515, depicted by
white spaces or white gaps between the glue regions. Accordingly, the glue-
based connection
is typically partial, and does not hold in place or glue the entirety of the
PV device 502 but
rather only portions thereof, thereby decreasing the mechanical resilience of
the produce,
and/or increasing the probability that the glue will fail or will weaken over
time. Additionally
or alternatively, such glue-based connection, which may have gaps or
imperfections, may not
hold the PV device securely and/or fixedly and/or hermetically.
[00131] Additionally or alternatively, a glue protrusion or over-spill 511
is shown, as an
example of various glue-based imperfections that may be caused by the gluing;
and such
imperfection may undesirably cover the product body 503 and/or the sunny-side
surface of the
PV device 502 (thereby reducing its operational efficiency).
[00132] Additionally or alternatively, one or more Glue Gaps 512 are also
shown, and they
may occur not only within the internal side of the PV device 502, but rather
they may occur
also at a side or a corner thereof, such that there may exist a spatial gap or
a spatial crater or an
undesired indentation (arrow 512 points to it) at the top side of the product.
[00133] Additionally or alternatively, the product has a non-flush surface 514
or a non-
uniform surface height, or suffers from an undesired "step"; as the PV device
502 does not
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exactly fit into the cavity of the pre-produced plastic body, but rather, the
PV device is slightly
recessed within such plastic body.
[00134] Additionally or alternatively, the PV device may be non-desirably
removed from
the plastic body; for example, due to mechanical shocks or forces, or due to
the product falling
or being subject to mechanical impacts; or due to the shaking of the product
(e.g., if the product
is moving or spinning, or if the user shakes or moves the product, or if the
user attempts to
remove the PV device from the plastic body, intentionally or unintentionally);
or due to the
glue weakening over time, or degrading over time due to age and/or heat and/or
environmental
changes (e.g., wetness, dryness, extreme temperatures).
[00135] Additionally or alternatively, small gaps or air-gaps or channels or
regions that lack
glue, may capture water or liquid or wetness, or sand or dust, or may trap
therein non-desired
materials; which may further contribute to weakening of the glue connection,
and/or to
shortening the life of the glue-based connection; or which may cause, directly
or indirectly,
damage to the PV device (e.g., trapped grains of sand may rub against the PV
device's sides).
[00136] Reference is made to Fig. 5B, which is an illustration of a prior
art hybrid non-
monolithic product 521; formed by gluing together two discrete and separate
objects: (i) a PV
device 502, and (ii) an already-molded plastic body 503. As shown, this
product suffers from
a different type of non-flush surface 516, such that the PV device 502 is
vertically higher
relative to the nearby top surface of the plastic body; and such the PV device
is slightly
protruding out of the PV body in a non-flush structure and with a non-desired
upward step
surrounding the edges of the PV device.
[00137] Reference is made to Fig. 5C, which is an illustration of a prior art
hybrid non-
monolithic product 531; formed by connecting together via a screw or nail or
pin 512 (or similar
mechanical connector) two discrete and separate objects: (i) a PV device 502,
and (ii) an
already-molded plastic body 503. As shown, this product suffers from a non-
flush surface; for
example, the PV device slightly protrudes upwardly out of the plastic body (as
demonstrated),
or conversely the PV device may be slightly recessed into the plastic body,
thereby causing the
product to have a non-desired non-flush surface.
[00138] Additionally or alternatively, the screw / nail / pin connection
mechanism may fail
due to mechanical shocks. Additionally or alternatively, and structural gaps
are demonstrated
(e.g., white gaps between the plastic body and the PV device), causing the PV
device to be
slightly movable or shaking or non-fixedly attached to the plastic body in a
non-desired or
imperfect manner.
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[00139] Additionally or alternatively, the PV device may be non-desirably
removed from
the plastic body; for example, due to mechanical shocks or forces, or due to
the product falling
or being subject to mechanical impacts; or due to a breakage of the screw or
nail or pin which
may break due to mechanical forces; or due to breakage of a "tooth" or a nut
or a protrusion or
other element through which the screw or nail or pin is inserted; or due to
intentional or non-
intentional removal of the screw or pin or nail by a user (e.g., the user
attempts to open a
screwed chamber of the plastic product, but mistakenly unscrews the screws the
connect the
PV device to the plastic body).
[00140] Additionally or alternatively, small gaps or air-gaps or ai channels,
may capture
water or liquids or wetness, or sand or dust, or may trap therein non-desired
materials; which
may further contribute to weakening of the connection, and/or to shortening
the life of the
connection; or which may cause, directly or indirectly, damage to the PV
device (e.g., trapped
grains of sand may rub against the PV device's sides).
[00141] Reference is made to Fig. 6A, which is a schematic illustration of a
monolithic
molded article 610, in accordance with some embodiments. The monolithic
article 610 includes
an operable PV device 612 that is integrally embedded in or incorporated in a
solidified molten
plastic or polymer 613; and that is fixedly and non-removably and non-
detachably held in place
via a molded connection, namely, via the same molding of plastic(s) and/or
polymer(s) that
created the non-PV-device portion of the monolithic molded article. In some
embodiments,
the molded article lacks any gaps or glue gaps, or glue protrusions or glue
craters, or side-gaps
or bottom-side gaps. In some embodiments, the top surface is flush and
perfect, and there is
no under-step or over-step or recess or protrusion; and the PV device is
neither recessed nor
protruding relative to the nearby top-surface of the plastic regions of the
article.
[00142] Reference is made to Fig. 6B, which is a schematic illustration of
another
monolithic molded article 620, in accordance with some embodiments. The
monolithic article
620 includes an operable PV device 622 that is integrally embedded in or
incorporated in a
solidified molten plastic or polymer 623. This article may be generally
similar to article 610
discussed above; yet one or more side-walls or side-panels or sides of the PV
device 622 may
be inwardly-slanted or inwardly-tapered, to achieve a particular structural or
functional goal,
and/or to improve or enhance or strengthen the molded connection of the PV
device and the
solidified molten plastic / polymer that is adjacent to it (e.g., by
increasing the surface area of
the PV device that is directly in touch with molten plastic / polymeric
materials).
[00143] Reference is made to Fig. 6C, which is a schematic illustration of
another
monolithic molded article 630, in accordance with some embodiments. The
monolithic article
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630 includes an operable PV device 632 that is integrally embedded in or
incorporated in a
solidified molten plastic or polymer 633. This article may be generally
similar to article 610
discussed above; yet one or more side-walls or side-panels or sides of the PV
device 632 may
be outwardly-slanted or outwardly-tapered, to achieve a particular structural
or functional goal,
and/or to improve or enhance or strengthen the molded connection of the PV
device and the
solidified molten plastic / polymer that is adjacent to it (e.g., by
increasing the surface area of
the PV device that is directly in touch with molten plastic / polymeric
materials), and/or to
provide a wedge-shape PV device that has increased or improved integral
attachment to its
surrounding.
[00144] Reference is made to Fig. 6D, which is a schematic illustration of
another
monolithic molded article 640, in accordance with some embodiments. The
monolithic article
640 includes a curved or non-planar or non-flat operable PV device 642 that is
integrally
embedded in or incorporated in a solidified molten plastic or polymer 643. The
solidified
molten plastic or polymer, which typically (but not necessarily) forms the
majority of the
article, also integrally and/or fixedly and/or securely and/or hermetically
holds in place the PV
device, without leaving any gaps or holes or protrusions. The PV device, or
its top surface or
"sunny side" surface, may be curved or concave or convex, or non-planar or non-
flat, or may
have other three-dimensional structure. The plastic regions of the monolithic
article 640 may
have a particular three-dimensional shape or structure to achieve particular
functional goals. In
some embodiments the top surface of the PV device, is precisely flush with the
top surface of
the molded plastic / polymer; such that the entirety of the top surface of the
article ¨ even
though it may be curved or convex or concave or non-planar ¨ is precisely
smooth, and lacks
any recesses or protrusions or steps.
[00145] Reference is made to Fig. 6E, which is a schematic illustration of
another monolithic
molded article 650, in accordance with some embodiments. The monolithic
article 650 includes
an operable PV device 652 that is integrally embedded in or incorporated in or
"buried in" or
"trapped in" or encapsulated within a Transparent or Translucent solidified
molten plastic or
polymer 653. The solidified molten plastic or polymer, which typically (but
not necessarily)
forms the majority of the article, also integrally and/or fixedly and/or
securely and/or
hermetically holds in place the PV device. In this example, the top surface of
the entire article
is planar or generally planar; although types of structures may be used.
[00146] Reference is made to Fig. 6F, which is a schematic illustration of
another monolithic
molded article 660, in accordance with some embodiments. The monolithic
article 660 includes
a curved or concave or convex or non-flat or nonplanar operable PV device 662
that is
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integrally embedded in or incorporated in or "buried in" or "trapped in" or
encapsulated within
a Transparent or Translucent solidified molten plastic or polymer 663. The
solidified molten
plastic or polymer, which typically (but not necessarily) forms the majority
of the article, also
integrally and/or fixedly and/or securely and/or hermetically holds in place
the PV device.
[00147] Some embodiments may be implemented by using a machine or an automated
or
semi-automatic production line, which may comprise, for example: a molding
unit, an injection
molding unit, a blow molding unit, a rotational molding unit, a heating unit,
a storage unit, a
cooling unit, an ejection unit; a placement unit or a mounting unit (e.g., to
place the PV device
at the exact location on the inner-side of the mold cavity or of the female
member of the mold);
a vacuum unit or suction unit; and/or other suitable units. The components and
units of the
system may be controlled by a controller or logic circuit, and optionally by a
computer which
may include, for example, a processor, a memory unit, a storage unit, input
units (e.g.,
keyboard, keypad, touch-screen, touch-pad, mouse, audio microphone), output
units (e.g.,
screen, touch-screen, audio speakers), wired and/or wireless transceivers
(e.g., Wi-Fi
transceiver, cellular transceiver, Bluetooth transceiver), a power source
(e.g., mains electricity,
battery, power cell), an Operating System (OS), drivers, applications, and/or
other hardware
components and/or software components.
[00148] In some embodiments, the PV device may be a flexible and/or rollable
and/or
foldable and/or bendable and/or non-planar PV cell having enhanced properties
of mechanical
impact absorption, the PV cell comprising: a semiconductor wafer that is
freestanding and
carrier-less, having a thickness, and having a first surface, and a having
second surface that is
opposite to said first surface; a set of non-transcending gaps, within said
semiconductor wafer,
wherein each non-transcending gap penetrates from the first surface of said
semiconductor
wafer towards the second surface of said semiconductor wafer but reaches to a
depth of
between 80 to 99 percent (or, 80 to 99.9 percent; or, 85 to 99.9 percent; or,
90 to 99.9 percent;
or, 95 to 99.9 percent) of the thickness (or the depth) of the semiconductor
wafer, and does not
reach said second surface; wherein each non-transcending gap does not entirely
penetrate
through an entirety of the thickness of said semiconductor wafer;
[00149] wherein said semiconductor wafer maintains at least 1 percent (or, in
some
embodiments, at least 0.1 percent) of the thickness of the semiconductor wafer
as an intact and
non-penetrated thin layer of semiconductor wafer that remains intact and non-
penetrated by
said non-transcending gaps; wherein said intact and non-penetrated thin layer
of semiconductor
wafer absorbs and dissipates mechanical forces and/or thermal forces and/or
thermal effects
and/or pressure forces.
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[00150] In some embodiments, each non-transcending gap is entirely filled with
one or more
filler materials that absorb mechanical shocks.
[00151] In some embodiments, between 50 percent and 99 percent of a volume of
each non-
transcending gap, is filled with one or more filler materials that absorb
mechanical shocks.
[00152] In some embodiments, between 1 percent and 50 percent of a volume of
each non-
transcending gap, is filled with one or more filler materials that absorb
mechanical shocks.
[00153] In some embodiments, said flexible PV cell is an integrated part of a
vehicular roof
or a vehicular body part.
[00154] In some embodiments, said flexible PV cell is an integrated part of: a
marine vessel
roof, or a marine vessel body part.
[00155] In some embodiments, said flexible PV cell is an integrated part of a
floating solar
device.
[00156] In some embodiments, said flexible PV cell is an integrated part of a
device selected
from the group consisting of: a drone, an aircraft, an aircraft body part, a
satellite, a spaceship,
a spacecraft.
[00157] In some embodiments, said flexible PV cell is an integrated part of a
building solar
roof or a PV-capable shingle.
[00158] In some embodiments, said flexible PV cell is an integrated part of: a
helmet, or a
wearable product, or a solar device that provides power to portable devices of
hikers.
[00159] In some embodiments, said first surface is at a first side of the
flexible PV cell that
faces a light source and that generates electricity from light using a
photovoltaic effect; wherein
said second surface is at a second, opposite, side of the flexible PV cell
which does not face
the light source and which does not generate electricity from light; wherein
each non-
transcending gap penetrates from said first side towards, but not reaching,
said second side;
wherein each non-transcending gap reaches to a depth of between 80 to 99
percent of the
distance between said first surface and said second surface.
[00160] In some embodiments, said first surface is at a first side of the
flexible PV cell that
does not face a light source and which does not generate electricity from
light; wherein said
second surface is at a second, opposite, side of the flexible PV cell which
faces a light source
and which generates electricity from light using a photovoltaic effect;
wherein each non-
transcending gap penetrates from said first side towards, but not reaching,
said second side;
wherein each non-transcending gap reaches to a depth of between 80 to 99
percent of the
distance between said first surface and said second surface.
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[00161] In some embodiments, said flexible PV cell is an Interdigitated Back
Contact (IBC)
solar cell having said semiconductor wafer with said set of non-transcending
gaps.
[00162] In some embodiments, said flexible PV cell is produced or is
integrated using a
process selected from: an injection molding process, a compression molding
process, an
autoclave process, a wet layup process, a roto-molding process, a blow-molding
process, a
Resin Transfer Molding (RTM) process, a thermoforming process, a Sheet Molding
Process
(SMC), a Prepreg Compression Molding (PCM) process, a vacuum forming process,
a reactive
injection molding process, a calendering process, a batch lamination process,
a semi-
continuous lamination process, a continuous lamination process, a roll-to-roll
lamination
process, a double-belt lamination process.
[00163] Some embodiments provide a method comprising: producing or
manufacturing or
making a molded article (e.g., molded plastic article, molded polymer article)
that integrally
holds and/or fixedly secures and/or fixedly holds and/or tightly holds and/or
non-detachably
holds and/or non-removably holds and/or hermetically holds, therein (e.g.,
buried or trapped
within the article) or thereon (e.g., such that at least one surface,
particular the active or "sunny
side" surface of the PV device is exposed at a corresponding surface of the
molded article), an
operable photovoltaic device (e.g., configured to absorb and convert light
into electric power).
Producing the molded article comprises: producing the molded article from a
raw material, or
from two or more raw materials, selected from the group consisting of: raw
plastic material(s),
raw polymeric material(s); by performing: (a) placing or mounting or arranging
or inserting,
within a mold at an inner-side of said mold cavity, an operable photovoltaic
device that is able
to convert light into electricity; and (b) performing a molding process that
is selected from the
group consisting of: injection molding, reactive injection molding, reaction
injection molding,
blow molding, rotational molding; wherein said performing comprises: heating
and melting
said raw material, and causing said material (upon its being heated and melted
or molten) to
acquire a shape (e.g., a particular three-dimensional shape or structure) that
complements (or
that corresponds to) a shape (or a three-dimensional structure) of an inner-
side of said mold,
and causing said operable photovoltaic device to become mechanically and
integrally held
and/or fixedly attached and/or securely attached and/or non-removably attached
and/or non-
detachably attached and/or hermetically connected in said article by adjacent
(or neighboring,
or directly-touching, or nearby, or surrounding) solidified molded region (or
solidified molded
portion) of said material; (c) after a cooling-off period of said mold and/or
of said material
and/or of said article and/or of the molding machine: opening said mold, and
removing or
extracting or ejecting or pulling-out said article from within said mold
cavity; wherein said
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article is a solid, molded-plastic or molded-polymer article which
mechanically holds integrally
therein or thereon said operable photovoltaic device via molded plastic or
molded polymer; for
example, without using screws or nails or pins or nuts or glue or adhesive for
such holding or
mechanical connection.
[00164] In some embodiments, said producing comprises: providing an injection-
molding
mold, having a male member and a female member which together define between
them a mold
cavity; when the injection-molding mold is open, placing the photovoltaic
device at an inner-
side of the female member of the injection-molding mold; closing the injection-
molding mold;
injecting into said mold cavity, in an injection molding process, molten
plastic material or
molten polymeric material; after a cooling-down period, opening the injection-
molding mold;
removing, from the opened injection-molding mold, a solid, molded-plastic or
molded-polymer
article which holds integrally therein or thereon said photovoltaic device.
[00165] In some embodiments, said placing comprises: temporarily securing the
photovoltaic device to the inner-side of the female member via suction force
or vacuum force.
[00166] In some embodiments, said placing comprises: temporarily securing the
photovoltaic device to the inner-side of the female member via an anchoring
mechanism.
[00167] In some embodiments, said placing comprises: temporarily securing the
photovoltaic device to the inner-side of the female member via an adhesive.
[00168] In some embodiments, said placing comprises: temporarily securing the
photovoltaic device to the inner-side of the female member via friction force
or pressure force.
[00169] In some embodiments, said placing comprises: temporarily securing the
photovoltaic device to the inner-side of the female member via a magnetic
force that attracts
(i) the photovoltaic device to (ii) the female member of the injection-molding
mold.
[00170] In some embodiments, the photovoltaic device has (i) a sunny-side
surface that is
configured to absorb light and convert it to electricity, and (ii) a dark-side
surface that is not
configured to absorb light and convert it to electricity; wherein the dark-
side surface is
generally opposite to the sunny-side surface; and said placing comprises:
placing the
photovoltaic device such that the sunny-side surface thereof is facing the
inner-side of the
female member of the injection-molding mold.
[00171] In some embodiments, the photovoltaic device has (i) a sunny-side
surface that is
configured to absorb light and convert it to electricity, and (ii) a dark-side
surface that is not
configured to absorb light and convert it to electricity; wherein the dark-
side surface is
generally opposite to the sunny-side surface; and said placing comprises:
placing the
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photovoltaic device such that the dark-side surface thereof is facing the
inner-side of the female
member of the injection-molding mold.
[00172] In some embodiments, said injecting comprises: injecting said molten
plastic
material or molten polymeric material such that the injected material
surrounds, some but not
all, of the sides of the photovoltaic device; and avoiding coverage or
obstructions by injected
material of the sunny-side surface of the photovoltaic device.
[00173] In some embodiments, said injecting comprises: melting a raw material
that is
selected from the group consisting of: transparent plastic, transparent
polymer, translucent
plastic, translucent polymer, plastic that allows at least partial passage of
light therethrough,
polymer that allows at least partial passage of light therethrough; injecting
molten raw material,
that is transparent or translucent, to surround and to encapsulate an entirety
of said photovoltaic
device.
[00174] In some embodiments, said injecting comprises: melting a raw material
that is
selected from the group consisting of: transparent plastic, transparent
polymer, translucent
plastic, translucent polymer, plastic that allows at least partial passage of
light therethrough,
polymer that allows at least partial passage of light therethrough; injecting
molten raw material,
that is transparent or translucent, to cover at least some of the sunny-side
surface of said
photovoltaic device.
[00175] In some embodiments, said photovoltaic device is operable to convert
light to
electricity prior to insertion of said photovoltaic device into the injection-
molding mold;
wherein said photovoltaic device remains operable to convert light to
electricity after it is
integrated, via injection molding, into said article. It is clarified that in
accordance with some
embodiments, the operable PV device is regarded as "operable" when it
generates electric
energy from light and/or when it converts light into electric energy and/or
when it is readily
operable to convert light into electric energy via the PV effect; even if, or
while, or when, such
PV device is not necessarily yet fully wired or fully connected to another
unit that collects or
aggregates or consumes or stores the generated electric charge and/or the
generated electric
current and/or the generated electric voltage.
[00176] In some embodiments, said placing comprises: temporarily mounting the
photovoltaic device on a non-planar region of the inner-side of the female
member.
[00177] In some embodiments, said photovoltaic device is a non-planar
photovoltaic device;
and said placing comprises: temporarily placing said non-planar photovoltaic
device at a non-
planar region of the inner-side of the female member; wherein the injecting
comprises: forming
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a non-planar contour of said injected-molded article immediately neighboring
said photovoltaic
device.
[00178] In some embodiments, performing the molding process comprises:
performing a
molding process that utilizes raw plastic material and/or raw polymeric
material, and also one
or more of: a foaming agent, a blowing agent, threads of glass fiber, chopped
glass fiber, strands
a mechanical reinforcement agent, threads of a mechanical reinforcement agent.
[00179] In some embodiments, performing the molding process comprises:
performing a
Reaction Injection Molding or a Reactive Injection Molding process that
utilizes polyurethane.
[00180] In some embodiments, said injecting comprises: entirely surrounding
(or trapping,
or burying, or encapsulating) an entirety of said operable photovoltaic
device, with injected
molten raw material that is transparent or translucent; creating by injection
molding a molded
article having said operable photovoltaic device entirely buried therein,
wherein a transparent
or translucent region of said molded article enables passage of light to an
active surface of said
operable photovoltaic device.
[00181] In some embodiments, said producing comprises: providing a blow-
molding mold,
having therein a mold cavity; placing the operable photovoltaic device within
the mold cavity,
at an inner-side of the blow-molding mold; forming a blow-molding parison from
a plastic
material and/or a polymeric material; placing the blow-molding parison inside
the mold cavity;
blowing pressured air or pressured gas into the blow-molding parison, and
inflating the blow-
molding parison from an original volume to an increased volume, and causing
the blow-
molding parison having said increased volume to acquire a complementing shape
that
complements a shape of the inner-side of the blow-molding mold; after a
cooling-down period:
opening the blow-molding mold, and removing therefrom a solid, molded-plastic
or molded-
polymer article which holds integrally therein or thereon said photovoltaic
device.
[00182] In some embodiments, said producing comprises: providing a rotational-
molding
mold, having therein a mold cavity; placing the operable photovoltaic device
within the mold
cavity, at an inner-side of the rotational-molding mold; inserting into the
mold cavity a pre-
defined amount of raw plastic material and/or raw polymeric material;
continuously rotating
and heating the rotational-molding mold for a first pre-defined time period
(Ti), and causing
the raw plastic material and/or raw polymeric material to melt and to be
pushed outwardly
towards the inner-side of the rotational-molding mold; stopping the heating of
the rotational-
molding mold, and continuously rotating and heating the rotational-molding
mold for a second
pre-defined time period (T2), and causing the raw plastic material and/or raw
polymeric
material to solidify during the rotating of the second pre-defined time period
(T2); after a
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cooling-down period: opening the rotational-molding mold, and removing
therefrom a solid,
molded-plastic or molded-polymer article which holds integrally therein or
thereon said
photovoltaic device.
[00183] In some embodiments, said placing comprises: placing said operable
photovoltaic
device which is flexible and rollable, and which comprises a semiconductor
substrate (or
semiconductor wafer) having a plurality of non-transcending craters (or non-
transcending gaps,
or non-transcending "bling gaps") that penetrate into, for example, from 80
percent to 99.9
percent (or, in some implementations, 85 to 99.9 percent; or 90 to 99.9
percent; or 95 to 99.9
percent), of a depth (or height, or thickness) of said semiconductor substrate
(or wafer);
wherein the plurality of non-transcending craters segment said semiconductor
substrate and
said operable photovoltaic device into a plurality of sub-regions, and provide
to said operable
photovoltaic device properties of absorption and dissipation of mechanical
forces and/or
mechanical shocks and/or mechanical pressure and/or thermal forces, and
provide to said
operable photovoltaic device an ability to remain operable even after being
subjected to high-
temperature and high-pressure molding. In some embodiments, filler material(s)
may fill,
partially or entirely, said non-transcending craters or at least some of them;
to further increase
the ability of the plurality of non-transcending craters of the PV device to
absorb and/or
dissipate mechanical forces and/or mechanical shocks and/or mechanical
pressure and/or
thermal forces, and/or to increase mechanical and/or thermal resilience of the
PV device, and/or
to enable the PV device to be flexible and/or rollable and/or foldable and/or
bendable, and/or
to enable the PV device to be curved or concave or convex or non-planar or non-
flat.
[00184] Some embodiments provide a production system or a manufacturing sytem,
comprising: a molding machine configured to produce a molded article that
integrally holds
therein or thereon an operable photovoltaic device; wherein the molding
machine is configured
to produce the molded article from a raw material selected from the group
consisting of: raw
plastic material, raw polymeric material; wherein the molding machine
comprises: (a) a
placement unit, configured to place within a mold cavity, at an inner-side of
said mold cavity,
an operable photovoltaic device that is able to convert light into
electricity, and (b) a molding
unit, configured to perform a molding process selected from the group
consisting of: injection
molding, blow molding, rotational molding; wherein said molding unit is
configured to heat
and melt said raw material, and to cause said material to acquire a shape that
complements a
shape of an inner-side of said mold, and to cause said photovoltaic device to
become
mechanically and integrally held by surrounding molding of said material; (c)
a mold opening
and ejection unit, that is configured to open said mold after a cooling-down
period, and is
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configured to remove said article from within said mold cavity; wherein said
article is a solid,
molded-plastic or molded-polymer article which mechanically holds integrally
therein or
thereon said photovoltaic device via molded plastic or molded polymer.
[00185] In some embodiments, the placement unit is configured to perform
placement of
said operable photovoltaic device which is flexible and rollable, and which
comprises
semiconductor substrate having a plurality of non-transcending craters that
penetrate into from
80 percent to 99.9 percent of a depth of said semiconductor substrate; wherein
the plurality of
non-transcending craters segment said semiconductor substrate and said
operable photovoltaic
device into a plurality of sub-regions, and provide to said operable
photovoltaic device
properties of absorption and dissipation of mechanical forces and/or
mechanical shocks and/or
mechanical pressure and/or thermal forces, and provide to said operable
photovoltaic device
an ability to remain operable even after being subjected to high-temperature
and high-pressure
molding.
[00186] Some embodiments provide a device or a product or a finished article
or an
apparatus comprising: a molded article that integrally holds therein or
thereon an operable
photovoltaic device; wherein the molded article is formed of a solidified
previously-molten
raw material selected from the group consisting of: raw plastic material, raw
polymeric
material; wherein the operable photovoltaic device is mechanically held and
integrated by said
molded article via a molded connection that molds at least two edges of said
operable
photovoltaic device connected via molding to one or more molded regions of
said molded
article; wherein the molded article, and the operable photovoltaic device, are
a single
monolithic article; wherein the operable photovoltaic device is held in place
only via molding
together with said one or more molded regions of said molded article, and not
via any screws
or any glue or any detachable attachment mechanism.
[00187] In some embodiments, the operable photovoltaic device has a first
surface and a
second, opposite surface; wherein the first surface is a sunny-side surface
that is configured to
absorb light and convert light to electricity; wherein the second surface is a
dark-side surface
that is not configured to absorb light and convert light to electricity;
wherein an entirety of the
sunny-side surface of the operable photovoltaic device is non-obstructed by
any solidified
molded plastic and/or by any solidified molded polymer; wherein solidified
molded plastic
and/or solidified molded polymer of said article, (i) covers and directly
touches at least 50
percent of an area of the dark-side surface of the operable photovoltaic
device (ii) and holds in
place said operable photovoltaic device.
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[00188] In some embodiments, the operable photovoltaic device has a first
surface and a
second, opposite surface; wherein the first surface is a sunny-side surface
that is configured to
absorb light and convert light to electricity; wherein the second surface is a
dark-side surface
that is not configured to absorb light and convert light to electricity;
wherein at least 75 percent
of the sunny-side surface of the operable photovoltaic device is non-
obstructed by any
solidified molded plastic and/or by any solidified molded polymer; wherein
solidified molded
plastic and/or solidified molded polymer of said article, (i) covers and
directly touches at least
50 percent of an area of the dark-side surface of the operable photovoltaic
device (ii) and holds
in place said operable photovoltaic device.
[00189] In some embodiments, the operable photovoltaic device has a first
surface and a
second, opposite surface; wherein the first surface is a sunny-side surface
that is configured to
absorb light and convert light to electricity; wherein the second surface is a
dark-side surface
that is not configured to absorb light and convert light to electricity;
wherein an entirety of the
sunny-side surface of the operable photovoltaic device is covered by (i)
solidified molded
plastic of said article that is transparent or translucent, and/or (ii)
solidified molded polymer of
said article that is transparent or translucent.
[00190] In some embodiments, the operable photovoltaic device has a first
surface and a
second, opposite surface; wherein the first surface is a sunny-side surface
that is configured to
absorb light and convert light to electricity; wherein the second surface is a
dark-side surface
that is not configured to absorb light and convert light to electricity;
wherein an entirety of the
operable photovoltaic device is buried and encapsulated within one or more
layers of (i)
solidified molded plastic of said article that is transparent or translucent,
and/or (ii) solidified
molded polymer of said article that is transparent or translucent; wherein
said one or more
layers enable passage of incoming light towards the sunny-side surface of the
operable
photovoltaic device.
[00191] In some embodiments, the operable photovoltaic device comprises two or
more
discrete photovoltaic units, that are electrically inter-connected in series
and/or in parallel via
an electrical circuit that collects and aggregates an electric charge that is
generated by
photovoltaic effect. In some embodiments, the molded article comprises: a
first article-region,
which integrally holds via molded plastic or molded polymer, a first discrete
photovoltaic unit;
a second article-region, which separately integrally holds via molded plastic
or molded
polymer, a second discrete photovoltaic unit; wherein the first discrete
photovoltaic unit and
the second discrete photovoltaic unit do not directly touch each other.
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[00192] In some embodiments, the operable photovoltaic device is securely and
fixedly held
in place within said molded article via an integrated connection that is
selected from the group
consisting of: an integrated injection-molded connection, an integrated blow-
molded
connection, an integrated rotational-molded connection. In some embodiments,
the mechanical
connection of the PV device to a surrounding or nearby plastic body or molded
body, or the
fixed holding of the PV device to such surrounding or nearby plastic body, is
nail-free and/or
screw-free and/or pin-free and/or glue-free and/or adhesive free.
[00193] In some embodiments, the apparatus is an apparatus selected from the
group
consisting of: a storage box, a cooler storage box, an ice storage box, a
shed, a shack, a toolshed,
a wall, a door, a roof segment, a shingle, a vehicular component, a
communication device, an
electronic device, a floating device.
[00194] In some embodiments, said operable photovoltaic device is flexible and
rollable,
and comprises a semiconductor substrate having a plurality of non-transcending
craters that
penetrate into from 80 percent to 99.9 percent of a depth of said
semiconductor substrate;
wherein the plurality of non-transcending craters segment said semiconductor
substrate and
said operable photovoltaic device into a plurality of sub-regions, and provide
to said operable
photovoltaic device properties of absorption and dissipation of mechanical
forces and/or
mechanical shocks and/or mechanical pressure and/or thermal forces, and
provide to said
operable photovoltaic device an ability to remain operable even after being
subjected to high-
temperature and high-pressure molding.
[00195] In some embodiments, the non-transcending craters begin at the dark-
side of the PV
device, and penetrate towards (but not reaching and not transcending through)
the sunny-side
of the PV device.
[00196] In some embodiments, the non-transcending craters begin at the sunny-
side of the
PV device, and penetrate towards (but not reaching and not transcending
through) the dark-
side of the PV device.
[00197] In some embodiments, some of the non-transcending craters begin at the
sunny-side
of the PV device, and penetrate towards (but not reaching and not transcending
through) the
dark-side of the PV device; and also, some other of the non-transcending
craters begin at the
dark-side of the PV device, and penetrate towards (but not reaching and not
transcending
through) the sunny-side of the PV device; and optionally, such non-
transcending craters may
be arranged in an alternating pattern or a zigzag pattern or other suitable
pattern or are arranged
at an offset relative to each other, such that two opposite-side non-
transcending craters do not
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meet each other and do not cause full penetration through the entire thickness
or the entire
depth of the semiconductor substrate or wafer.
[00198] Functions, operations, components and/or features described herein
with reference
to one or more embodiments, may be combined with, or may be utilized in
combination with,
one or more other functions, operations, components and/or features described
herein with
reference to one or more other embodiments, or vice versa.
[00199] While certain features of some embodiments have been illustrated and
described
herein, many modifications, substitutions, changes, and equivalents may occur
to those skilled
in the art. Accordingly, the claims are intended to cover all such
modifications, substitutions,
changes, and equivalents.
