GB2439412A

GB2439412A - Flexible solar panel

Info

Publication number: GB2439412A
Application number: GB0708225A
Authority: GB
Inventors: Hamish David Rowan
Original assignee: J&D Wilkie Ltd
Current assignee: J&D Wilkie Ltd
Priority date: 2006-06-23
Filing date: 2007-04-27
Publication date: 2007-12-27
Anticipated expiration: 2027-04-27
Also published as: GB2439412B; GB0708225D0

Abstract

A flexible solar panel 2 comprises warp members 4 and weft members 6 in a woven, non-woven or knitted form where the warp and/or the weft members 4, 6 enable the conversion of solar energy into electrical energy. The warp members 4 are connected together with electrical connectors 8, 10 connected to a positive terminal 12. The weft members 6 are also connected by electrical connectors 14, 16 connected to a negative terminal 18. In one embodiment the warp members 4 comprise a p-i-n structure while well members 6 are conductive yarns. The solar panel is lightweight and easy to fold or roll away and can be used as awnings, sails, kites, tents, roofing, clothing, or as a covering for football pitches or swimming pools.

Description

I

A SOLAR PANEL WITH WARP AND WEFT MEMBERS

This invention relates to a solar panel and, more especially, this invention relates to a solar panel with warp and weft members.

Solar panels are well known. They convert solar energy into electrical energy. The solar panels are produced in a wide variety of shapes and sizes, and they are used for a wide variety of different applications. The known solar panels are either rigid or such that they possess only a limited degree of flexibility. This rigidity or limited flexibility limits the potential application of the known solar panels.

It is an aim of the present invention to reduce the above mentioned problem.

Accordingly in one non-limiting embodiment of the present invention there is provided a solar panel comprising warp members and weft members, the warp and weft members being in a woven, non-woven or knitted form in the solar pane), and the warp and/or the weft members being such that they enable the conversion of solar energy into electrical energy.

The solar panel of the present invention is thus a solar panel that has warp and weft members, and that Is able to capture sunlight and convert the solar energy into electrical energy. Because the solar panel has the warp and weft members in the woven, non-woven or knitted form, the solar panel it is able to be produced such that it can flex and bend in virtually any desired direction. Thus the solar panel of the present invention is able to be used in a wide variety of applications which are excluded due to the known solar panels being rigid or insufficiently flexible. By way of example, it is mentioned that the solar panel of present invention may be useful for caravan awnings, yacht sales, kites, camping, roofing for detached building such for example as sheds, horse blankets, tents, rucksacks, jackets, other clothing, military applications and applications in the motor industry. The solar panel is able to power remote battery-operated equipment such for example as mobile telephones, MP3 players, radios, and emergency equipment such for example as alarms, and GPS signaling equipment.

Generally, the solar panel can be used to power anything that is suitable, portable and electrical. Other applications for the solar panel of the present invention may be in low heating applications such for example as frost protection as might be required for a football pitch or other area.

The solar panel may be produced to be lightweight, easy to fold away, or easy to roll away and pull out as might be required for covering the areas such for example as football pitches or swimming pools. The flexibility of the solar panel gives it the ability to be thrown over a rock or the like in order to capture the solar energy from the sun.

The solar panel may be one in which the warp and the welt members are such that the warp members are of a first construction, the weft members are of a second construction, one of the first and second constructions is conductive and transparent with a p-i-n junction, and the other one of the first and second constructions is conductive.

Preferably, the warp members are of the first construction, and the weft members are of the second construction. The reverse arrangement may however be employed if desired.

The solar panel may be one in which the first construction comprises a film, a first coating which is on one side of the film and which is of an amorphous n-type semiconductor, a second coating which is on the side of the first coating farthest from the film and which is of an intrinsic semiconductor alloy, and a third coating which is on the side of the second coating farthest from the first coating and which is of a p-type amorphous semiconductor.

The amorphous n-type semiconductor coating is preferable phosphorous doped silicon. Other types of materials may be used for the amorphous n-type semiconductor coating.

Preferably, the semiconductor alloy coating is an intrinsic semiconductor alloy coating and one which is preferably an alloy of the semiconductors of the first and third coatings. Other semiconductor alloy coatings may be employed.

The p-type amorphous semiconductor is preferably boron doped silicon. Other types of p-type amorphous semiconductor may be employed.

In an alternative embodiment of the invention, the solar panel is one in which the first construction comprises a film and a single coating of self-separate p-i-n material.

In all embodiments of the invention, the second construction may comprise a conductive yam or wire. The conductive yarn or wire is preferably made of copper. Other conductive metals may be employed.

Conductive non-metals may also be employed.

Preferably the solar panel includes a holding member which holds together the warp and the weft members. The holding member may be a yam. Other types of holding members may be employed.

The solar panel may be one in which the warp and the weft members are woven together such that they alternately pass on top of and underneath each other. Alternatively, the solar panel may be one in which the warp and the weft members are woven together such that they lie as two layers one on top of the other. Other weaving constructions may be employed for the warp and the weft members. In an alternative construction for the solar panel, the warp and the weft members may be non-woven or they may be knitted.

The solar panel as manufactured and sold may include positive and negative electrical terminals. Any suitable and appropriate type of positive and negative electrical terminals may be employed.

The solar panel may include an insulating coating on an underside of the solar panel. The insulating coating may be a rubber coating, a coating of a plastics material, or a composite coating.

The solar panel may include an anti-reflecting coating on the top surface of the solar panel. The anti-reflective coating is preferably an anti- * reflective film. Any suitable and appropriate material may be employed for the anti-reflective coating.

The solar panel may comprise a solar layer of film in either the warp members or the weft members, leaving the other non-used members to act as a carrier for the solar layer of film. The solar layer of the film may generate a positive and negative output.

Embodiments of the invention will now be described solely by way of example and with reference to the accompanying drawings in which: Figure 1 is a top plan view of a first solar panel of the present invention; Figure 2 is a cross section through part of a second solar panel according to the present invention; Figure 3 illustrates a weaving process that may be employed for weaving together warp and weft members to form a solar panel of the present invention; Figure 4 shows a first weave pattern for a solar panel of the present invention; and Figure 5 shows a second and preferred weave pattern for a solar panel of the present invention.

Referring to Figure 1, there is shown a solar panel 2 comprising warp members 4 and weft members 6. The warp members 4 and the weft members 6 are woven together. The warp members 4 and the welt member 6 are such that they enable the conversion of solar energy into electrical energy. The warp members 4 are connected together with electrical connecting members 8, 10. The electrical connecting members 8 10 are themselves connected to a positive electrical terminal 12. Similarly, the weft members 6 are connected together by electncal connecting members 14, 16. The electrical connecting members 14, 16 extend to a negative electrical terminal 18. The positive and negative electrical terminals 12, 18 respectively form power connections by which the solar panel 2 can be connected as desired, for example to a piece of portable electncat equipment needing electrical power.

Referring now to Figure 2, there is shown a cross section through a solar panel 20. The solar panel 20 is such that it comprises warp members 22, only one of which is shown. The solar panel 20 is such that it also comprises weft members 24. The warp members 22 are conductive and transparent and they are provided with a p-i-n junction. The warp members 22 may be in the form of a film, with the p-i-n Junction being formed by a first coating 26 which is on one side of the film as shown in Figure 2 and which is of an amorphous n-type semiconductor, a second coating 28 which is on a side of the first coating 26 farthest from the warp members 22 in the form of the film and which is of an intrinsic semiconductor alloy, and a third coating which is on the side of the second coating 28 farthest from the first coating 26 and which is of a p-type amorphous semiconductor. Because the warp members 22 are conductive and transparent, they allow sunlight to penetrate a top protective layer of the solar panel 20 and reach the p-i-n-junction. The amorphous n-type semiconductor coating is preferably phosphorous doped silicon. The semiconductor alloy coating is preferably an alloy of the semiconductors of the first and the third coatings 26, 30. The p-type amorphous semiconductor is preferably boron doped silicon.

In the embodiment of the invention shown in Figure 2, the warp members 22 in the form of the transparent and conductive film may be provided with the first, second and third coatings 26, 28, 30 as three separate coatings. The formed p-i-n-junction allows the flow of electrons necessary to produce current flow and therefore to convert solar energy into electrical energy.

In an alternative embodiment of the invention (not shown), instead of having three separate coatings 26, 28, 30, a self-separating p-i-n compound could be used in the form of a single coating. This would save on production time and costs as compared with using three separate coatings.

Referring now to Figure 3, there is shown a process for producing the solar panel of the present invention. In Figure 3, warp material 32 is unwound from a roll 34. The warp material 32 is combined with weft material 36. The warp material 32 and the weft material 36 is appropriately formed into strips/yams. The formed warp members and the weft members are then woven together using holding members 38. Preferably the holding members 38 are in the form of yams but they may be in other forms if desired.

Figure 4 shows a first weaving pattern that may be employed for a solar panel of the present invention. In Figure 4, it Will be seen that warp and weft members are woven together such that they aftemately pass on top of and underneath each other. This type of weaving may be regarded as weft insertion weaving.

Figure 5 shows an alternative and preferred weaving pattern for a solar panel of the present invention. In Figure 5, the warp and the weft members are woven such that they lie as two layers one on top of the other.

The warp and welt members are held together with third holding members.

This type of weaving is preferred as it causes less damage to the solar panel being formed, as compared to using a needle which will penetrate the solar panel being formed.

It is to be appreciated that the embodiments of the invention described above with reference to the accompanying drawings have been given by way of example only and that modifications may be effected. Thus, for example, the conductive underside of a solar panel of the present invention may be covered with an insulator, for example of a plastics material, a rubber material, or a suitable compound. Also, an anti-reflective film may be added to the top of the solar panel. This anti-reflective film may be added during weaving, or it may be added after weaving. Usually the warp members wilt be connected together to produce the negative feed, and the weft members will be connected together to produce the positive feed.

The reverse arrangement may however be employed in Which the case the warp members will be connected together to produce the positive feed, and the weft members will be connected together to produce the negative feed.

The solar panel of the present invention may be such that the positive and negative terminals power any suitable and appropriate type of electrical device, or charge a battery. In alternative applications, the solar panel may be constructed to be larger for area covering purposes such for example as covering a football pitch to protect it from frost damage. In an alternative construction, the warp and the weft members may be together in a non-woven form or a knitted form instead of in the woven form. In an alternative construction, the solar panel may use a solar layer of film in either the warp members or the weft members, leaving the other non-used members to act as a carrier for the solar layer of film. The solar layer of film may be able to generate a positive and negative output instead of the warp and weft members of the solar panel of the present invention being used for providing positive and negative outputs. I0

Claims

CLAIMS

1. A solar panel comprising warp members and weft members, the warp and weft members being in a woven, non-woven or knitted form in the solar panel, and the warp and/or the weft members being such that they enable the conversion of solar energy into electrical energy.

2. A solar panel according to claim I in which the warp and the weft members are such that the warp members are of a first construction, the weft members are of a second construction, one of the first and second constructions is conductive and transparent with a p-i-n-junction, and the other one of the first and second constructions is conductive.

3. A solar panel according to claim 2 in which the warp members are of the first construction, and the weft members are of the second construction.

4. A solar panel according to claim 2 or claim 3 in which the first construction comprises a film, a first coating which is on one side of the film and which is of an amorphous n-type semiconductor, a second coating which is on the side of the first coating farthest from the film and which is of an intrinsic semiconductor alloy, and a third coating which is on the side of the second coating farthest from the first coating and which is of a p-type amorphous semiconductor.

5. A solar panel according to claim 4 in which the amorphous n-type semiconductor coating is phosphorous doped silicon.

6. A solar panel according to claim 4 or claim 5 in which the semiconductor alloy coating is an alloy of the semiconductors of the first and the third coatings.

7. A solar panel according to any one of claims 4-6 in which the p-type amorphous semiconductor is boron doped silicon.

8. A solar panel according to any one of daim 2 or claIm 3 in which the first construction comprises a film and a single coating of a self-separating n-i-p material.

9. A solar panel according to any one of claims 2 -8 in which the second construction comprises a conductive yam or wire.

10. A solar panel according to claim 9 in which the conductive yarn or wire is of copper.

11. A solar panel according to any one of the preceding claims and induding a holding member which holds together the warp and the weft.

members.

12. A solar panel according to claim 11 in which the holding member is a yam.

13. A solar panel according to any one of the preceding claims in which the warp and weft members are woven together such that they alternately pass on top of and underneath each other.

14. A solar panel according to any one of claims I -12 in which the warp and the wefi members are woven together such that they lie as two layers one on top of the other.

15. A solar panel according to any one of the preceding claims and including positive and negative electrical terminals.

16. A solar panel according to any one of the preceding claims and including an insulating coating on an underside of the solar panel.

17. A solar panel according to claim 16 in which the insulating coating is a rubber coating or a coating of a plastics material.

18. A solar panel according to any one of the preceding claims and including an anti-reflective coating on a top surface of the panel.

19. A solar panel according to claim 18 in which the anti-reflective coating is an anti-reflective film.

20. A solar panel according to any one of the preceding claims and comprising a solar layer of film in either the warp members or the weft members, leaving the other non-used members to act as a carrier for the solar layer of film.

21. A solar panel according to claim 20 in which the solar layer of the film generates a positive and negative output.

22. A solar panel substantially as herein described with reference to the accompanying drawings.