CN111919380A

CN111919380A - Three-dimensional photovoltaic module that 3D printed

Info

Publication number: CN111919380A
Application number: CN201980014372.0A
Authority: CN
Inventors: 丹尼尔·S·克拉克
Original assignee: Individual
Current assignee: Individual
Priority date: 2018-02-20
Filing date: 2019-02-18
Publication date: 2020-11-10
Also published as: SG11202007571XA; WO2019164782A1

Abstract

A 3D printed three-dimensional photovoltaic system that allows for the absorption of solar energy from various angles. The solar structure has a plurality of solar cells in a substantially flat 3D polygonal solar frame or a substantially flat mountain-like 3D solar frame, and a reflective surface located below the solar frame to reflect light, wherein the solar frame has an uneven surface. A plurality of solar cells are oriented at various angles relative to the reflective surface. The plurality of solar cells are configured to receive sunlight.

Description

Three-dimensional photovoltaic module that 3D printed

Cross Reference to Related Applications

This application claims the benefit of U.S. application No. 15/900,779 filed on day 2/20 of 2019, which is a continuation-in-part application of U.S. application No. 14/835,578 and publication No. 9,899,956 filed on day 8/25 of 2017, which claims priority to U.S. provisional patent application No. 62/041,480 filed on day 8/25 of 2014, U.S. provisional patent application No. 62/130,397 filed on day 3/9 of 2015, and U.S. provisional patent application No. 62/132,256 filed on day 3/12 of 2015. The contents of the above-referenced application are incorporated by reference in their entirety.

Technical Field

The present invention relates generally to solar energy devices. More specifically, the present invention is a three-dimensional photovoltaic module having a plurality of solar cells arranged in a flat polygonal arrangement, a flat mountain-like polygon, or a polyhedron, wherein each of the plurality of solar cells absorbs light from a different angle. The present invention relates to a 3D printed solar energy and a 3D printed solar energy frame configured to accommodate a plurality of solar cells.

Background

The sun is the ultimate source of energy, providing the earth with sufficient solar energy so that only a small portion of the solar energy, if efficiently converted to electrical energy, would be sufficient to meet all the needs of humans. Solar energy is becoming more and more efficient, it is low pollution and one of the unlimited renewable energy sources. It provides an effective substitute for fossil fuels and a promising long-term solution to the energy crisis.

Solar technology is generally classified in a broad sense as passive solar technology or active solar technology according to the manner in which it captures, converts, and distributes solar energy. Active solar technology includes the use of photovoltaic panels to harness energy. The light harvesting method to convert solar energy into electricity includes two key steps that determine the overall efficiency of the method, namely: 1) light absorption, and 2) charge collection. The solar panel or photovoltaic cell industry is developing at a high rate and has great market potential.

Two-dimensional flat solar panels are common panels for solar energy harvesting, which are found mounted on roofs of domestic and commercial property. However, two-dimensional panels have certain limitations, such as insufficient energy conversion due to the relative lack of direct incident light, especially in high-altitude areas. Light at an abnormal angle of incidence affects the efficiency of a flat solar panel, which is particularly evident when considering not only the movement of the sun in its daily cycle, but also the movement of the sun in its annual cycle.

Conventional solar panels include a plurality of small solar cells dispersed over a large area that can work together to provide sufficient electrical power, which occupies a large space, making it difficult to install such solar panels in many commercial settings. In addition to space limitations, the reflectivity of the solar cell surface also greatly affects the yield of solar panels, although existing anti-reflective coating techniques are used to address the reflectivity problem. In addition to space limitations and two-dimensional flat panel designs, solar panels known in the prior art have further limitations due to the use of conventional metal contact lines and busbars in solar cells.

Disclosure of Invention

Accordingly, there is a need in the art for efficient solar panel designs to maximize the conversion of sunlight to electricity. It is an object of the present invention to provide a three-dimensional photovoltaic module that allows for absorption of solar energy from various angles in an arrangement of three hundred and sixty degrees. The present invention includes a solar structure having a plurality of solar cells positioned around a solar frame arranged in a polyhedron. Each of the plurality of solar cells is bifacial, wherein each of the plurality of solar cells absorbs light from outside the solar structure and from an interior space of the solar structure. The concentrating photovoltaic lens guides light into and encloses the interior space.

The solar structure is connected to the base unit, allowing the solar structure to rotate freely, thereby cooling the solar structure and increasing the efficiency of the present invention. The solar structure is connected to a rotating base of the floor unit, wherein the rotating base magnetically floats around a magnetic mount that allows the solar structure to rotate. In addition, the plurality of acoustic levitation modules stabilize the levitation of the rotating base around the magnetic base. A module support structure is also provided to allow optimal positioning of a plurality of three-dimensional photovoltaic modules.

In other embodiments of the present invention, a 3D printed three-dimensional solar photovoltaic system is provided, comprising a solar structure comprising a substantially flat 3D polygonal solar frame having an uneven surface, and a plurality of solar cells disposed on the substantially flat solar frame; a reflective surface located below the solar frame, the reflective surface configured to reflect sunlight, wherein the plurality of solar cells are oriented at various angles relative to the reflective surface, wherein the plurality of solar cells are configured to receive sunlight.

In certain embodiments, the solar frame is produced by a 3D printer.

In certain embodiments, the plurality of solar cells are produced by a 3D printer. In certain embodiments, the entire system is produced by a 3D printer.

In certain embodiments, the plurality of solar cells are configured to receive sunlight from the top and bottom of the photovoltaic system.

In certain embodiments, the solar frame is transparent.

In certain embodiments, the plurality of solar cells are bifacial such that the plurality of solar cells are configured to receive sunlight directly from the sun and from the reflective surface.

In some embodiments, the plurality of solar cells are back-to-back, capable of absorbing from both the top and bottom of the design.

In some embodiments, the solar frame is a lattice.

In some embodiments, the sunlight is configured to pass through a lattice structure of the solar frame.

In certain embodiments, the reflective surface is selected from the group consisting of mirrors, glass beads, reflectives, ceramic beads, microcrystalline ceramic beads, and diamond sheets, and combinations thereof.

In certain embodiments, each solar cell of the plurality of solar cells comprises a first photovoltaic cell.

In certain embodiments, the first photovoltaic cell comprises a plurality of nanoscale pores and an absorber wafer; and the plurality of nanoscale apertures traverse into the absorber wafer

In certain embodiments, the first photovoltaic cell comprises an absorber wafer, a contact layer, and a subsequent contact; and wherein the subsequent contact is located on the absorber wafer opposite the contact layer.

In certain embodiments, each solar cell of the plurality of solar cells is circumferentially connected to the solar frame.

In certain embodiments, the system includes a concentrating photovoltaic lens having a pentagonal shape located within the solar frame.

In certain embodiments, the plurality of solar cells form a polyhedral arrangement.

In some embodiments, the plurality of solar cells are triangular, pentagonal, or 3D polygonal.

In certain embodiments, the plurality of solar cells may have various shapes and configurations that fit into the solar frame.

In certain embodiments, the substantially flat 3D polygonal solar frame is made of a plastic or polymeric material.

In certain embodiments, the substantially flat 3D polygonal solar frame is made of a plurality of sections having a pentagonal configuration.

Another object of the invention is achieved by providing a three-dimensional solar photovoltaic system comprising a solar structure comprising: a substantially flat solar frame having an uneven surface, and a plurality of solar cells (e.g., as shown in fig. 18) disposed on the substantially flat solar frame; a reflective surface located below the solar frame, the reflective surface configured to reflect sunlight, wherein the plurality of solar cells are oriented at various angles relative to the reflective surface, wherein the plurality of solar cells are configured to receive sunlight.

Drawings

FIG. 1 is a perspective view of the present invention, a floor unit, a solar structure, a module support structure, and a plurality of acoustic suspension modules.

Fig. 2 is a front view of the present invention with the rotating base magnetically levitated above the magnetic base.

FIG. 3 is a perspective view of a solar structure attached to a rotating base, with a concentrating photovoltaic lens mounted thereto.

FIG. 4 is a perspective view of a solar structure connected to a rotating base with a concentrating photovoltaic lens removed.

Fig. 5 is a bottom plan view of the swivel base and solar structure.

Fig. 6 is a cross-sectional view of a first photovoltaic cell of each of a plurality of solar cells.

Fig. 7 is a cross-sectional view of a second photovoltaic cell of each of a plurality of solar cells.

Fig. 8 is a cross-sectional view of the rotating base and the plurality of magnets, showing a first pole and a second pole of each of the plurality of magnets.

Fig. 9 is a diagram illustrating electrical connections between the speaker and the frequency generator of each of the plurality of acoustic levitation modules.

Fig. 10 is a perspective view of the present invention with the swivel base directly connected to the module support structure.

FIG. 11 is a perspective view of a magnetic base of the base unit with a central bore for generating a magnetic vortex.

Fig. 12 is a perspective view of a solar frame wherein the solar frame 5 is spherical to reduce drag when the solar structure is rotated.

Fig. 13 is another perspective view of a solar frame having a spherical shape.

Fig. 14 is a perspective view of a plurality of solar cells curved to fit the spherical shape of a solar frame.

Fig. 15 is a perspective view of a plurality of solar cells arranged in a polyhedron.

Fig. 16 is a schematic diagram of one embodiment of the present invention directed to a 3D printed three-dimensional solar photovoltaic system having a plurality of solar cells on a frame.

Fig. 17 is a schematic view of the embodiment of the invention of fig. 16 without a plurality of solar cells, showing only the solar frame.

Fig. 18 is a perspective view of the embodiment of the invention of fig. 16 without a plurality of solar cells, showing only the solar frame.

Fig. 19 is a two-dimensional plan view of the structure of fig. 18 showing how a plurality of triangular solar cells form a pentagonal structure.

Fig. 20 is a view of some contemplated polygons of the shape of a plurality of solar cells.

Fig. 21 is a view of a pentagonal structure of a set of triangular solar cells.

Fig. 22 is a portion of a solar frame for a triangular solar cell. The solar frame has a pinhole that allows light to pass through the solar frame.

Fig. 23 is a grid or lattice structure whereby the solar frame is irregular and can accommodate solar cells of various configurations and shapes.

FIG. 24 is a representation of the manner in which sunlight illuminates a solar design in a bifacial manner. The reflective element allows sunlight to be absorbed at the top of the system and reflected sunlight can be absorbed through the lower portion of the system.

Fig. 25 is an embodiment in which triangular cells are shown in a 3D hexagonal pattern integrated within a solar frame.

Fig. 26A-26C disclose configurations of solar frames supporting solar cells in various configurations.

FIGS. 27A-27D disclose configurations of solar frames supporting solar cells of various configurations

FIGS. 28A-28C disclose microscopic views of fly's eye in a hexagonal configuration of polymer solar subcells.

Fig. 29 and 30 are photographs showing various solar cells within a solar frame.

Detailed Description

The contents of US15/900,779, filed 2/20/2019, the contents of U.S. patent application No. 14/835,578, filed 8/25/2017, the contents of U.S. provisional patent application No. 62/041,480, filed 8/25/2014, the contents of U.S. provisional patent application No. 62/130,397, filed 3/9/2015, and the contents of U.S. provisional patent application No. 62/132,256, filed 3/12/2015 are all incorporated by reference into this application as if fully set forth herein.

All illustrations in the drawings are for the purpose of describing selected forms of the invention and are not intended to limit the scope of the invention.

The present invention relates to a three-dimensional photovoltaic module that allows for the absorption of solar energy from various angles in a three hundred and sixty degree arrangement. Referring to fig. 1, the three-dimensional photovoltaic module includes a floor unit 1, a solar structure 2, a module support structure 4, and a plurality of acoustic levitation modules 3. The solar structure 2 provides a means for absorbing light and converting the light into electrical current. The solar structure 2 is supported by the floor unit 1, the floor unit 1 in turn being supported by the module support structure 4. The plurality of acoustic levitation modules 3 help stabilize the solar structure 2 and the floor unit 1.

Referring to fig. 3-4, the solar structure 2 is tightly coupled to the base unit 1 and includes a solar frame 20, a plurality of solar cells 21, and a concentrating photovoltaic lens 28. The solar frame 20 supports a plurality of solar cells 21 and defines the overall shape of the solar structure 2. The solar frame 20 is a framework showing a plurality of open spaces in which a plurality of solar cells are placed. Each of the plurality of solar cells 21 is circumferentially connected to the solar frame 20, wherein the plurality of solar cells 21 are distributed in a polyhedral arrangement. In a preferred embodiment of the invention, each of the plurality of solar cells 21 is triangular, however in other embodiments of the invention it is possible for the plurality of solar cells 21 to be shaped differently.

Referring to fig. 3, similar to each of the plurality of solar cells 21, a concentrating photovoltaic lens 28 is circumferentially connected to the solar frame 20. The concentrating photovoltaic lens 28 is disposed around the solar frame 20 opposite the floor unit 1, wherein the concentrating photovoltaic lens 28 is disposed around the top of the solar frame 20. As shown in fig. 4, the solar structure 2 and the floor unit l together show an interior space 5, wherein the concentrating photovoltaic lens 28 allows light to enter the interior space 5 through the solar structure 2. The concentrating photovoltaic lens 28 focuses and encloses the light in the interior space 5. In a preferred embodiment of the invention, the concentrating photovoltaic lens 28 is a fresnel lens, however, other types of lenses may be used in other embodiments of the invention. Furthermore, in a preferred embodiment of the present invention, the solar frame 20 is transparent, wherein light can enter the interior space 5 through the solar frame 20.

Each of the plurality of solar cells 21 is designed to absorb light from both sides, wherein each of the plurality of solar cells 21 comprises a first photovoltaic cell 22. In a preferred embodiment of the invention, the first photovoltaic cell 22 is designed to absorb light from two opposite faces. In this way, the first photovoltaic cell 22 is able to absorb sunlight from outside the solar structure 2, as well as sunlight from the interior space 5, wherein the sunlight from the interior space 5 is dispersed by the concentrating photovoltaic lens 28.

Referring to fig. 3, in certain embodiments, the solar cells are arranged to form a pentahedron arrangement. The solar structure 2 has a multi-layer curved upper outer surface with a hollow core. In certain embodiments, each cell 22 includes nanomaterials distributed between a metal contact layer at the bottom and a silicon wafer layer at the top. The nanomaterials sandwiched between the top and bottom layers of the solar cell include copper nanowires, liquid metal carbon nanotubes, and nanoparticles. The solar cell also includes a bus bar and a contact wire. For example, in one pentahedral arrangement, each face of the curved upper outer surface comprises a triangular silicon slice at the top. For example, the solar cell 22 includes a hollow core having a thickness of 250 microns.

In one embodiment, the silicon layer at the top of the solar cell 22 is etched by piranha to remove organic residues from the silicon surface. Piranha etching essentially comprises a mixture of sulfuric acid and hydrogen peroxide, which is used to remove organic residues from the surface of a substrate.

In one embodiment, the silicon wafer layer at the top of the solar cell 22 is etched with a plurality of nanometer-scale holes to reduce reflectivity, thereby increasing the efficiency of solar energy conversion. In addition, these holes allow photons to penetrate the cell interior and bounce around to generate increased electrical energy. For example, 100 micron diameter holes are etched in the silicon surface at the top layer. The nanopores on the top silicon surface cause the solar cell 22 to present a black surface appearance.

In an embodiment, the three-dimensional solar panel device of the present invention further comprises a motor connected to the central shaft, configured to rotate the main plate unit in the fixed shaft. The solar cell unit 22 is coated with nanomaterials along the inner and outer surfaces by employing a sealed chamber that forms a tornado-like vortex of nanoparticles.

In one embodiment, the solar cell unit 22 is coated with nanomaterials along the inner and outer surfaces by employing a sealed chamber that forms a tornado-like vortex of nanoparticles. The solar cell unit 22 is located inside the sealed chamber to effectively connect the solar cell with the nanoparticles rotating in the vortex.

In one embodiment, the three-dimensional solar panel apparatus is mounted on a tree structure, reducing space consumption and can be used in a wide range of industrial and commercial settings, including parking lots, traffic lights, street lights, rooftops, leisure parks, residential campuses, and solar farms. The aesthetic design of the three-dimensional solar panel device attracts more consumers and greatly enhances market potential. The three-dimensionally curved upper outer surface of the base unit is substantially distributed with a plurality of facets comprising solar cells to be provided with nano-scale holes etched on the top layer such that the curved upper outer surface appears like a magnified view of the eyes of a fly that maximizes the reception of solar energy by enhancing photon penetration energy, thereby increasing the energy conversion output of the solar panel apparatus.

In certain embodiments, the micro solar subcells are 3D printed and then electroplated with copper. Liquid solar material is sprayed over the subcells to form a decentralized solar panel, which has no authoritative or failure center. The subcells are referred to as the micro hexagonal lattices in fig. 28.

In certain embodiments, the battery is made by perovskite. In certain embodiments, the solar subcells are coated with copper indium gallium selenide and perovskite in series.

Referring to fig. 6, the first photovoltaic cell 22 includes an absorber wafer 24, a contact layer 25, and a subsequent contact 26. The absorber wafer 24 is a semiconductor that absorbs light energy and provides a p-n junction to generate current. The absorber wafer 24 may provide single or multiple junctions depending on the embodiment and intended use of the invention. In a preferred embodiment of the present invention, absorber wafer 24 is crystalline silicon providing a single junction, however in other embodiments of the present invention absorber wafer 24 may also be a thin film technology, with multiple thin film technologies forming a multi-junction or other photovoltaic material.

With further reference to fig. 6, a subsequent contact 26 is located on the absorber wafer 24 opposite the contact layer 25, wherein the subsequent contact 26 and the contact layer 25 complete a circuit. In the preferred embodiment 5 of the present invention, the subsequent contact 26 is a variety of nanomaterials including copper nanowires, liquid metal carbon nanotubes and other nanoparticles. The plurality of nanomaterials function to promote light absorption, thereby enhancing the overall efficiency of each of the plurality of solar cells 21. In a preferred embodiment of the present invention, the plurality of nanomaterials are applied to the absorber wafer 24 by placing the absorber wafer 24 in a closed chamber and forming a tornado-like vortex of nanoparticles, wherein the nanoparticles are dispersed and attached to the absorber wafer 24.

The contact layer 25 is a transparent metal oxide or similar material applied to the absorber wafer 24 that, in addition to serving as a contact, allows light to pass through to the absorber wafer 24. In a preferred embodiment of the invention, the contact layer 25 is located close to the inner space 5, wherein the subsequent contact 26 is outside the solar structure 2. However, in other embodiments of the invention, the first photovoltaic cell 22 may be flipped over with the subsequent contact 26 located near the interior space 5 and the contact layer 25 located around the outside of the solar structure 2.

In other embodiments of the invention, contacts other than a variety of nanomaterials may be used as the subsequent contacts 26. The subsequent contact 26 is located around the absorber wafer 24 opposite the contact layer 25, with the absorber wafer 24 sandwiched between the contact layer 25 and the subsequent contact 26. In one embodiment, the subsequent contact 26 includes a plurality of busbars and a plurality of contact lines linearly distributed around the absorber wafer 24. In another embodiment, the subsequent contact 26 is formed by printed electronics. The contact layer 25 and subsequent contacts 26 provide a means for circulating current through the circuit.

In some embodiments of the present invention, the first photovoltaic cell 22 further comprises a plurality of nanoscale pores 27, as shown in FIG. 6. The plurality of nanoscale holes 27 traverse into the absorber wafer 24 and act to reduce the reflectivity of the absorber wafer 24. Further, the plurality of nanoscale apertures 27 allow photons to penetrate the first photovoltaic cell 22 and cause the photons to bounce to generate increased electrical energy.

In certain embodiments of the present invention, the first photovoltaic cell 22 may also be etched by piranha. More specifically, the plurality of nanomaterials are etched by piranha. Piranha solution is a mixture of sulfuric acid and hydrogen peroxide that is used to remove organic residues from a variety of nanomaterials.

In an alternative embodiment of the invention, each of the plurality of solar cells 21 further comprises a second photovoltaic cell 23, wherein the first photovoltaic cell 22 and the second photovoltaic cell 23 absorb light from different sides of the solar structure 2. Referring to fig. 4, the second photovoltaic cell 23 of each of the plurality of solar cells 21 is located adjacent to the internal space 5, wherein the second photovoltaic cell 23 of each of the plurality of solar cells 21 absorbs the light dispersed within the internal space 5 through the concentrating photovoltaic lens 28. The first photovoltaic cell 22 is positioned adjacent to the second photovoltaic cell 23, opposite the interior space 5 for each of the plurality of solar cells 21, wherein the first photovoltaic cell 22 absorbs light around the exterior of the solar structure 2.

Referring to fig. 7, the second photovoltaic cell 23 includes an absorber wafer 24, a contact layer 25 and a subsequent contact 26. The absorber wafer 24 of the second photovoltaic cell 23 is a semiconductor that absorbs light energy and provides a p-n junction to generate an electrical current. The absorber wafer 24 of the second photovoltaic cell 23 may provide single or multiple junctions, depending on the embodiment and intended use of the invention. In a preferred embodiment of the invention, the absorber wafer 24 of the second photovoltaic cell 23 is a crystalline silicon providing a single junction, however, in other embodiments of the invention, the absorber wafer 24 of the second photovoltaic cell 23 may also be a thin film technology, multiple thin film technologies forming multiple junctions, or other photovoltaic materials.

With further reference to fig. 7, the subsequent contact 26 of the second photovoltaic cell 23 is located on the absorber wafer 24 of the second photovoltaic cell 23 opposite the contact layer 25 of the second photovoltaic cell 23, wherein the subsequent contact 26 of the second photovoltaic cell 23 and the contact layer 25 of the second photovoltaic cell 23 complete an electrical circuit. In a preferred embodiment of the invention, the subsequent contact 26 of the second photovoltaic cell 23 is a plurality of nanomaterials including copper nanowires, liquid metal carbon nanotubes and other nanoparticles. The plurality of nanomaterials of the second photovoltaic cell 23 act to promote light absorption, thereby enhancing the overall efficiency of each of the plurality of solar cells 21. In a preferred embodiment of the invention, the plurality of nanomaterials of the second photovoltaic cell 23 are applied to the absorber wafer 24 of the second photovoltaic cell 23 by placing the absorber wafer 24 of the second photovoltaic cell 23 in a closed chamber and forming a tornado-like vortex of nanoparticles, wherein the nanoparticles are dispersed and adhered to the absorber wafer 24.

The contact layer 25 of the second photovoltaic cell 23 is an opaque or transparent metal oxide or similar material which is applied to the absorber wafer 24 of the second photovoltaic cell 23 and serves as a contact. Similarly, the contact layer 25 of the first photovoltaic cell 22 may also be opaque. The contact layer 25 of the second photovoltaic cell 23 is positioned adjacent to the contact layer of the first photovoltaic cell 22. In this way, the subsequent contact 26 of the first photovoltaic cell 22 is on the outside of the solar structure 2, while the subsequent contact 26 of the second photovoltaic cell 23 is on the inside of the solar structure 2, adjacent to the inner space 5.

In other embodiments of the invention, contacts other than a plurality of nanomaterials may be used as the subsequent contact 26 of the second photovoltaic cell 23. The subsequent contact 26 of the second photovoltaic cell 23 is positioned around the absorber wafer 24 of the second photovoltaic cell 23 opposite the contact layer 25 of the second photovoltaic cell 23, wherein the absorber wafer 24 of the second photovoltaic cell 23 is sandwiched between the contact layer 25 of the second photovoltaic cell 23 and the subsequent contact 26 of the second photovoltaic cell 23. In an embodiment, the subsequent contacts 26 of the second photovoltaic cell 23 comprise a plurality of busbars and a plurality of contact wires; the plurality of busbars of the second photovoltaic cell 23 and the plurality of contact lines of the second photovoltaic cell 23 are linearly distributed around the absorber wafer 24 of the second photovoltaic cell 23. In another embodiment, the contact layer 25 of the second photovoltaic cell 23 and the subsequent contact 26 of the second photovoltaic cell 23 provide a means for circulating current through the circuit.

In certain embodiments of the present invention, the second photovoltaic cell 23 further comprises a plurality of nanoscale pores 27, as shown in FIG. 7. The plurality of nanoscale holes 27 of the second photovoltaic cell 23 penetrate across the absorber wafer 24 of the second photovoltaic cell 23 and act to reduce the reflectivity of the absorber wafer 24 of the second photovoltaic cell 23. Furthermore, the plurality of nanoscale apertures 27 of the second photovoltaic cell 23 allow photons to penetrate the second photovoltaic cell 23 and cause the photons to bounce to generate increased electrical energy.

In certain embodiments of the present invention, the second photovoltaic cell 23 may also be etched by piranha. More specifically, the plurality of nanomaterials of the second photovoltaic cell 23 are etched by the piranha. The piranha solution is a mixture of sulfuric acid and hydrogen peroxide that is used to remove organic residues from the nanomaterials of the second photovoltaic cell 23.

Referring to fig. 1-2, the base unit 1 includes a magnetic base 10, a rotating base 11, and a plurality of magnets 12. The solar structure 2 is closely attached to the rotating base 11 and each of the plurality of magnets 12 is closely attached to the rotating base 11. A plurality of magnets 12 are positioned circumferentially around the rotating base 11, wherein the plurality of magnets 12 are evenly distributed around the rotating base 11. Further, each of the plurality of magnets 12 includes a first pole 13 and a second pole 14; the first pole 13 is a north pole and the second pole 14 is a south pole, or vice versa. The first pole 13 is positioned intermediate the rotating base 11 and the second pole 14 as shown in fig. 8. The first pole 13 has a magnetic field pointing outwards, towards the rotating base 11, while the second pole 14 has a magnetic field pointing outwards, away from the magnet holder 10. The same orientation of each of the plurality of magnets 12 causes the magnetic fields of the first and

second poles

13, 14 of adjacent magnets to repel each other, thereby forming a magnetic vortex.

Referring to fig. 2, a rotating base 11 is positioned between the magnetic base 10 and the solar structure 2, wherein the rotating base 11 is suspended above the magnetic base 10 and/or surrounds the magnetic base 10. The magnetic base 10 provides a magnetic force to levitate the rotating base 11 at a fixed distance from the magnetic base 10. The orientation of the plurality of magnets 12 around the rotating base 1l causes a magnetic vortex which in turn, in combination with the magnetic force of the magnetic base 10, causes the rotating base 11 and consequently the solar structure 2 to rotate about a vertical axis. Furthermore, the magnetic base 10 has a central hole, as shown in fig. 11, to promote magnetic swirl. The rotation of the rotating base 11 and the solar structure 2 serves to cool the solar structure 2 and thus improve the efficiency of the invention.

Referring to fig. 5, the base plate unit 1 further comprises a ball bearing 15 positioned through the swivel base 11, wherein the ball bearing 15 is positioned concentrically with the swivel base 11. The ball bearing 15 provides a mechanism for an opening through which the electrical wires can be positioned so that they do not become twisted as the rotating base 11 and solar structure 2 rotate about the magnetic mount 10. The electric wire is used to connect each of the plurality of solar cells 21 to a storage battery, a power line, an inverter, and the like.

Referring to fig. 12-14, in a preferred embodiment of the present invention, the solar structure 2 is spherical in shape, and thus the solar frame 20 is designed without angles. Furthermore, each of the plurality of solar cells 21 is curved to fit the contour of the solar frame 20. The spherical design of the solar structure 2 is desirable because it reduces the drag of the solar structure 2 as the solar structure 2 rotates.

Referring to fig. 1, a plurality of acoustic levitation modules 3 are positioned circumferentially around the base unit 1, wherein the plurality of acoustic levitation modules 3 are used to stabilize the rotating base 11 as the rotating base 11 levitates and rotates over the magnetic base 10. Each of the plurality of acoustic levitation modules 3 includes a speaker 30 and a frequency generator 31, wherein the frequency generator 31 is electrically connected to the speaker 30 as shown in fig. 9. The loudspeaker 30 of each of the plurality of acoustic levitation modules 3 is oriented towards the chassis unit 1, wherein the loudspeaker 30 generates sound waves at a frequency determined by the frequency generator 31 and directs the sound waves towards the chassis unit 1. The plurality of acoustic levitation modules 3 use acoustic radiation pressure to controllably move the rotating base 11 and the solar structure 2 as the rotating base 11 and the solar structure 2 hover around the magnetic base 10.

Referring to fig. 1-2, module support structure 4 provides a base for adjacent connection to the floor unit 1, wherein the module support structure 4 raises the floor unit 1, and thus the solar structure 2, wherein the solar structure 2 can be optimally positioned to receive maximum light exposure. Module support structure 4 comprises a main support 40 and a branch 41, wherein branch 41 is terminally connected to main support 40. The floor unit 1 is connected adjacent to the branch 41, opposite the main support 40; more specifically, the magnetic base 10 is adjacently connected to the module support structure 4.

The module support structure 4 also allows multiple three-dimensional photovoltaic modules to be supported in the same location. A plurality of subsequent branches may be terminally connected to the main support 40, wherein each branch of the plurality of subsequent branches supports a subsequent floor unit 1 and a subsequent solar structure 2. The plurality of subsequent branches may each have a different length and be staggered so as to optimally position each of the three-dimensional photovoltaic modules such that each of the three-dimensional photovoltaic modules receives a maximum amount of illumination. This in turn simultaneously increases the efficiency of using multiple three-dimensional photovoltaic modules.

Referring to fig. 10, in other embodiments of the invention, the magnetic mount 10 may not be included, wherein the rotating base 11 is rotationally connected to the module support structure 4. The rotating base 11 is connected terminally to the drive shaft of a motor for driving the rotation of the rotating base 11 and the solar structure 2. The motor may be powered directly by the solar structure 2 or any secondary power source may be used to power the motor.

The invention relates to 3D printing solar frames to produce 3D solar systems. The present invention includes 3D printing and additive manufacturing techniques to create a system for absorbing solar energy.

Various 3D and additive manufacturing techniques (e.g., SLS) may be used to create the structure of the solar frame. Other techniques such as volumetric printing may also be used to create the solar frame.

In some embodiments of the invention, a 3D printer is used for 3D printing these plastic 3D structures to produce flat 3D versions compatible with current flat panel solar panel production lines.

The present invention relates to a 3D printer for producing these plastic 3D structures. The plastic 3D structure is assembled into a solar panel. Bifacial solar cells (triangles) can be placed in the design. Or the solar triangles may be placed on the top and bottom of the design, back to back with each other, so that the design has twice the amount of light absorption compared to a conventional flat solar panel.

In certain embodiments, the present invention has a textured lattice in its plastic 3D printed structure, making the present invention capable of absorbing sunlight from the top and bottom of the design. In some embodiments, there is a diamond-backed reflective plate/mirror or other reflective substitute that reflects light upward so that the underlying solar cells absorb sunlight simultaneously with the top of the model.

Fig. 16 is another embodiment of the present invention. In fig. 16, a three-dimensional solar photovoltaic system 1000 is shown. In certain embodiments, the solar photovoltaic system comprising the solar frame is printed by a 3D printer. The 3D printer requires complicated printing of the uneven surface of the solar frame.

In fig. 16, a triangular solar cell 1030 integrated within a solar frame 1010 is shown. The solar cell may be in other configurations such as polygonal, square, rectangular, pentagonal, hexagonal, heptagonal, octagonal, and decagonal, as well as other configurations suitable for solar cell design. Fig. 20 shows these configurations.

In fig. 17, a solar frame 1010 having a window 1020 is provided. The solar frame 1010 is shown with an uneven surface so that the orientation of the solar cells placed within the frame may be irregular or may have an organized clutter so that the cells may be directed toward different angles. Orienting the solar cells at different angles towards the sun allows for maximum absorption of sunlight.

In fig. 18, a solar frame 1010 shows an organized structure with an uneven surface so that the solar frame can position solar cells in windows 1020 at various angles with respect to the sun.

Fig. 19 is a two-dimensional plan view of the structure of fig. 18, showing how a plurality of triangular solar cells form a pentagonal structure. In some embodiments, the pentagonal structures may be replaced by other sets of triangular solar cells (e.g., hexagonal, heptagonal, octagonal, and decagonal sets).

Fig. 21 is a view of a pentagonal structure of a set of triangular solar cells. The polygonal structure shown is a 3D structure: which is convex and has the highest center point. The polygonal structure is configured to accommodate five triangular solar cells and provide an economical arrangement to absorb solar energy.

Fig. 22 is a portion of a solar frame for a triangular solar cell. The solar frame has a pinhole that allows light to pass through the frame. Pinholes in the solar frame allow light to pass through the solar frame when the solar cell is placed within the solar frame. The pinhole allows for maximum light absorption in the system.

In some embodiments, the solar frame is transparent, and in other embodiments, the pinhole is sufficient to allow light to pass through the solar frame.

In certain embodiments, the system comprises a pin-like hole in the 3D printed plastic frame.

Figure 23 is a grid or mesh structure that makes the solar frame irregular and can accommodate solar cells of various configurations and shapes. In some embodiments, the 3D solar frame is configured to accommodate solar cells of various shapes and sizes. The net structure of the solar frame is elastic and can be deformed into various solar cell shapes. The grid shown in fig. 23 is an example of a grid that may be used in a plastic 3D printed solar frame.

Fig. 24 is an illustration of a solar frame and reflective elements such that sunlight can be absorbed at the top of the system and reflected sunlight can be absorbed through the lower portion of the system.

In fig. 24, the sun is shown with its rays and transmitted solar energy. Some solar ray energy passes through solar energy system 1000, and in particular solar frame 1010. These rays are then shown impinging on a reflective surface or plate 1040 and are then reflected back into the lower portion of the system 1000.

In fig. 25, another embodiment is shown in which the cells are shown integrated into a solar frame 1010 in a sheet-like fashion. For maximum solar efficiency, the frame may be arranged at an angle of 45 degrees or about 45 degrees.

In certain embodiments, the plurality of solar subcells are all 3D printed.

Fig. 26A-26C disclose configurations of solar frames that support solar cells in various configurations.

Fig. 27A-27D disclose configurations of solar frames supporting solar cells in various configurations.

Fig. 28A-28C disclose hexagonal configurations of micro-subcells of a solar frame.

In certain embodiments, the plurality of solar cells are bifacial solar cells such that the solar cells can absorb direct sunlight and reflected light from the reflective element (which is a mirror, a panel, or a diamond-faced panel).

In other embodiments, the plurality of solar cells are single-sided solar cells such that the absorbing surface of the top solar cell on top of the system faces the sun and the absorbing surface of the bottom solar cell faces the reflective element. In this manner, the system can capture both direct sunlight and reflected sunlight from the reflective element, thereby absorbing energy more efficiently within the same surface area of the solar energy system configuration.

Although the present invention has been described with respect to preferred embodiments thereof, it should be understood that many other possible modifications and variations could be made without departing from the spirit and scope of the invention as hereinafter claimed.

Claims

1. A3D printed three-dimensional solar photovoltaic system comprising:

a solar structure comprising:

a substantially flat 3D polygonal solar frame having an uneven surface, and

a plurality of solar cells disposed on the substantially flat solar frame;

a reflective surface located below the solar frame, the reflective surface configured to reflect sunlight;

wherein the plurality of solar cells are oriented at various angles relative to the reflective surface;

wherein the plurality of solar cells are configured to receive sunlight.

2. The system of claim 1, wherein the solar frame is produced by a 3D printer.

3. The system of claim 1, wherein the plurality of solar cells are configured to receive sunlight from the top and bottom of the photovoltaic system.

4. The system of claim 1, wherein the solar frame is transparent.

5. The system of claim 1, wherein the plurality of solar cells are bifacial such that the plurality of solar cells are configured to receive sunlight directly from the sun and from the reflective surface.

6. The system of claim 1, wherein the plurality of solar cells are back-to-back, capable of absorbing from both the top and bottom of the design.

7. The system of claim 1, wherein the solar frame is a lattice.

8. The system of claim 7, wherein sunlight is configured to pass through the lattice structure of the solar frame.

9. The system of claim 1, wherein the reflective surface is selected from the group consisting of mirrors, glass beads, reflectives, ceramic beads, microcrystalline ceramic beads, and diamond sheets, and combinations thereof.

10. The system of claim 1, wherein each solar cell of the plurality of solar cells comprises a first photovoltaic cell.

11. The system of claim 10, wherein the first photovoltaic cell comprises a plurality of nanoscale pores, and an absorber wafer; and the plurality of nanoscale apertures traverse into the absorber wafer.

12. The system of claim 1, wherein each solar cell of the plurality of solar cells is circumferentially connected to the solar frame.

13. The system of claim 1, further comprising a concentrating photovoltaic lens having a pentagonal shape located within the solar frame.

14. The system of claim 1, wherein the plurality of solar cells form a polyhedral arrangement.

15. The system of claim 1, wherein the plurality of solar cells are triangular, pentagonal, or 3D polygonal.

16. The system of claim 1, wherein the substantially flat 3D polygonal solar frame is made of plastic or polymeric material.

17. The three-dimensional photovoltaic module of claim 1, wherein the substantially flat 3D polygonal solar frame is comprised of a plurality of sections having a polygonal configuration.

18. A three-dimensional solar photovoltaic system comprising:

a solar structure comprising:

a substantially flat solar frame having an uneven surface, and

a plurality of solar cells disposed on the substantially flat solar frame;

a reflective surface located below the solar frame, the reflective surface configured to reflect sunlight,

wherein the plurality of solar cells are oriented at various angles relative to the reflective surface,

wherein the plurality of solar cells are configured to receive sunlight.

19. The system of claim 18, wherein the solar frame is a substantially flat mountain-like 3D solar frame.

20. A three-dimensional photovoltaic module, comprising:

a solar structure;

the solar structure comprises a solar frame; a plurality of solar cells; and a concentrating photovoltaic lens, each of the plurality of solar cells comprising a first photovoltaic cell;

each solar cell of the plurality of solar cells is circumferentially connected to the solar frame;

the concentrating photovoltaic lens is circumferentially connected to the solar frame;

the concentrating photovoltaic lens is disposed around the solar frame; and

the solar structure defines an interior space.