Flexible photovoltaic cell, and methods and systems of producing it
A flexible photovoltaic (PV) cell having enhanced properties of mechanical impact absorption, includes: 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 that first surface; a set of non-transcending gaps within the semiconductor wafer. Each non-transcending gap penetrates from the first surface towards the second surface but reaches to a depth of between 80 to 99 percent of the thickness of the semiconductor wafer, and does not reach said second surface. Each non-transcending gap does not entirely penetrate through an entirety of the thickness of the semiconductor wafer. The semiconductor wafer maintains at least 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 the non-transcending gaps. The intact and non-penetrated thin layer of semiconductor wafer absorbs and dissipates mechanical forces.
1. A flexible photovoltaic (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 of the thickness 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,
wherein said semiconductor wafer maintains at least 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,
wherein each non-transcending gap is entirely filled with an elastomer that absorbs mechanical shocks and dissipates mechanical forces.
2. The flexible PV cell of claim 1 ,
wherein said flexible PV cell is an integrated part of a floating solar device.
3. The flexible PV cell of claim 1 ,
wherein 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.
4. The flexible PV cell of claim 1 ,
wherein said flexible PV cell 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.
5. A method comprising:
manufacturing a flexible photovoltaic (PV) cell having enhanced properties of mechanical impact absorption, by performing:
(a) producing a semiconductor wafer that is freestanding and carrier-less,
having a thickness, and having a first surface, and having a second surface that is opposite to said first surface;
(b) producing a set of non-transcending gaps, within said semiconductor wafer,
by making each non-transcending gap penetrate from the first surface of said semiconductor wafer towards the second surface of said semiconductor wafer, reaching to a depth of between 80 to 99 percent of the thickness of the semiconductor wafer, and not reaching said second surface;
and by preventing each non-transcending gap from entirely penetrating through an entirety of the thickness of said semiconductor wafer,
and by maintaining at least 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,
entirely filling each non-transcending gap with an elastomer that further absorbs mechanical shocks and dissipates mechanical forces.
6. The method of claim 5 , further comprising:
(c) entirely filling each of the non-transcending gaps, with one or more filler materials that provide thermal durability to said semiconductor wafer.
7. The method of claim 5 ,
wherein said manufacturing comprises manufacturing said flexible photovoltaic (PV) cell which is an integrated part of a floating solar device.
8. The method of claim 5 ,
wherein said flexible PV cell 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.
9. Method of claim 5 ,
wherein 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.
10. The flexible PV cell of claim 1 ,
wherein said elastomer, that entirely fills said non-transcending gap, and that absorbs mechanical shocks and dissipates mechanical forces, comprises Ethylene-Vinyl Acetate (EVA).
11. The flexible PV cell of claim 1 ,
wherein said elastomer, that entirely fills said non-transcending gap, and that absorbs mechanical shocks and dissipates mechanical forces, comprises High-Impact Polystyrene (HIPS).
12. The flexible PV cell of claim 1 ,
wherein said elastomer, that entirely fills said non-transcending gap, and that absorbs mechanical shocks and dissipates mechanical forces, comprises a block copolymer of polystyrene-polybutadiene.
13. The flexible PV cell of claim 1 ,
wherein said elastomer, that entirely fills said non-transcending gap, and that absorbs mechanical shocks and dissipates mechanical forces, comprises a block copolymer of polystyrene-polyisoprene.
14. The flexible PV cell of claim 1 ,
wherein said elastomer, that entirely fills said non-transcending gap, and that absorbs mechanical shocks and dissipates mechanical forces, comprises polybutadiene neoprene.
15. The flexible PV cell of claim 1 ,
wherein said elastomer, that entirely fills said non-transcending gap, and that absorbs mechanical shocks and dissipates mechanical forces, comprises polyol.
16. The flexible PV cell of claim 1 ,
wherein said elastomer, that entirely fills said non-transcending gap, and that absorbs mechanical shocks and dissipates mechanical forces, improves a capability of the flexible PV cell to assume a non-planar structure.
17. The flexible PV cell of claim 1 ,
wherein a Specific Weight of an entirety of the flexible PV cell is smaller than one,
wherein the flexible PV cell autonomously floats on water.
18. The flexible PV cell of claim 1 ,
wherein the flexible PV cell is part of an article selected from the group consisting of:
a roof, a roof shingle, a wall, a vehicle, an aircraft, a drone, a boat.