Classifications

• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
  • H02S20/00—Supporting structures for PV modules
  • H02S20/30—Supporting structures being movable or adjustable, e.g. for angle adjustment
  • H02S20/32—Supporting structures being movable or adjustable, e.g. for angle adjustment specially adapted for solar tracking
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
  • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
  • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
  • H01L31/042—PV modules or arrays of single PV cells
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
  • H01L31/00—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
  • H01L31/04—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
  • H01L31/042—PV modules or arrays of single PV cells
  • H01L31/043—Mechanically stacked PV cells
• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
  • H02S40/00—Components or accessories in combination with PV modules, not provided for in groups H02S10/00 - H02S30/00
  • H02S40/20—Optical components
  • H02S40/22—Light-reflecting or light-concentrating means
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
  • Y02E10/00—Energy generation through renewable energy sources
  • Y02E10/50—Photovoltaic [PV] energy
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
  • Y02E10/00—Energy generation through renewable energy sources
  • Y02E10/50—Photovoltaic [PV] energy
  • Y02E10/52—PV systems with concentrators
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
  • Y02E70/00—Other energy conversion or management systems reducing GHG emissions
  • Y02E70/30—Systems combining energy storage with energy generation of non-fossil origin

Definitions

• Various embodiments relate generally to modular wall systems, methods, and devices and, more specifically, relate to wall sections that can be used to create walls for a pyramidal shaped structure.
• an embodiment provides a solar panel assembly.
• the solar panel assembly includes a mounting post and at least three triangular shaped panels.
• Each triangular shaped panel is a solar panel responsive to a first spectrum of light and transparent to a second spectrum of light.
• the solar panel assembly also includes at least three hinges. For each triangular shaped panel, an associated hinge connects the triangular shaped panel to the mounting post.
• the at least three triangular shaped panels can move between a flat configuration (e.g., along a single plane) and an inverted pyramid configuration.
• the at least three triangular shaped panels form a first solar panel layer, and the solar panel assembly also includes one or more additional solar panel layers.
• Each of the additional solar panel layers being responsive to an associated spectrum of light.
• an embodiment provides wall section which has a shell defining a plurality of pyramidal shapes. Each pyramidal shape has at least three triangular sides.
• the wall section includes at least one solar panel assembly as described above disposed in an associated pyramidal shape.
• An angle of the at least three triangular sides with respect to the base range between 5° and 85°.
• an embodiment provides a solar panel assembly.
• the solar panel assembly includes a mounting post and at least three triangular shaped panels. Each triangular shaped panel is a solar panel responsive to a first spectrum of light and transparent to a second spectrum of light.
• the solar panel assembly also includes an energy storage component.
• the energy storage component and the at least three triangular shaped panels define an inverted pyramid configuration where the energy storage component is located in a first portion of the inverted pyramid configuration and the at least three triangular shaped panels is located in a second, exterior facing portion of the inverted pyramid configuration (e.g., where the energy storage component is in the point of the pyramid shape and the shaped panels are in the portion nearest the base).
• Figure 07 shows ball socket detail of the outer shell section for a panel rack plug.
• Figure 08 shows a first insulative layer of the male conductive frame.
• Figure 10 shows contact detail of the first conductive layer.
• Figure 14 shows an alternate cross section of the male conductive frame.
• Figure 16 shows male frame connector tabs for a first conductive layer of the male conductive frame.
• Figure 18 shows the frame positioned with the pyramid mold core.
• Figure 19 shows“keyhole” slots in carbon fiber sheet.
• Figure 22 shows the outside edges of the carbon fiber sheet pulled up, exposing the“foot print” of the housing.
• Figure 23 shows two vents cut into the carbon fiber sheet.
• Figure 25 introduces the clamp base.
• Figure 26 introduces four slide action slides.
• Figure 27 shows the slide action slides positioned on the clamp base.
• Figure 28 shows the inline clamps in position on the clamp base.
• Figure 29 introduces the inline clamp hardware.
• Figure 31 shows the inline clamps with handles up, closing against the slide action slides.
• Figure 32 shows the clamping action against the carbon fiber sheet into a boss on the male -A- conductive frame.
• Figure 33 shows a close-up detail of the area affected by the clamping action.
• Figure 34 shows a close-up detail of area where the carbon fiber wraps over the top of the male conductive frame and back onto itself.
• Figure 35 shows the carbon fiber sheet completely wrapped over itself.
• Figure 36 shows circular cutouts into the top layer of the carbon fiber sheet.
• Figure 37 introduces a locking post.
• Figure 38 reveals the bottom side of the locking post.
• Figure 39 shows all four locking posts in position.
• Figure 40 shows the wrap trimmed to expose the post slots.
• Figure 41 shows wrap trimmed to expose bosses with ball socket detents.
• Figure 42 shows one set of three oval slots cut into the second layer of the carbon fiber sheet.
• Figure 43 shows a detail of the profile of the oval slots on top of the“keyhole” slots.
• Figure 44 shows a complete male side wall and bosses.
• Figure 45 shows the male side wall oriented to show the grooves.
• Figure 47 shows a cutaway view of a solar panel prepared to be inserted into a male side wall.
• Figure 49 shows the solar panel in place in the male side wall.
• Figure 50 shows a cropped detail of two solar panel posts in the male side wall.
• Figure 52 shows a detail of the solar panel locked in position.
• Figure 54 shows a solar panel module locked in place in a male side wall.
• Figure 55 shows a connection rack.
• Figure 56A shows a cutaway view of the connection rack.
• Figure 56B shows the extracted circuits of the connection rack.
• Figure 57 shows a connection rack oriented to join a male side wall.
• Figure 60 shows a cutaway detail of a conductive lead on the solar panel post locked into a detent socket.
• Figure 62 shows a detail of a cross section of the ball socket snap fits.
• Figure 63 shows a view of the ball joints locked into the ball snap fits.
• Figure 64 introduces the remaining connection racks.
• Figure 65 shows all connection racks locked into place.
• Figure 66 shows a second module of solar panels separated and ready to be locked into place.
• Figure 67 shows the second module of solar panels locked into place.
• Figure 68 shows a completed assembly of a male solar panel section from the solar panels side.
• Figure 69 shows a close-up view of a solar panel.
• Figure 70 shows exaggerated detail of the casing of the panel.
• Figure 71 shows a female -B- wall section from the connection rack side.
• Figure 72 shows a detail of the combined female connector ends.
• Figure 73 shows a detail of the connector ends of the female first conductive layer.
• Figure 74 shows a detail of the female second insulative layer.
• Figure 75 shows a detail of the connector end’s female second conductive layer.
• Figure 76 shows a detail of the isolated connector ends of the female first conductive layer.
• Figure 77 shows a detail of the isolated female second insulative layer.
• Figure 79 shows male -A- and female -B- wall sections in relative position.
• Figure 80A shows a detail of the -A- male connector ends and -B- female connector ends.
• Figure 80B shows a close-up of an O-ring groove.
• Figure 80C shows a cross section of the comer exposing the O-ring groove and the O- ring.
• Figure 81 shows male -A- and female -B- wall sections locked in place in a modular array.
• Figure 82 shows alternate view of male -A- and female -B- wall sections locked in place in the modular array.
• Figure 83 shows a cropped detail of the junction of -A- & -B- sections which form a post slot.
• Figure 84 shows a cropped detail of a laterally exploded junction of -A- & -B- sections.
• Figure 85 shows a cutaway dimetric view of the laterally exploded -A- & -B- junction with a locking post from a backing wall section.
• Figure 86 shows an alternate view of the laterally exploded -A- & -B- junction and locking post.
• Figure 87 shows an -A- & -B- junction joined together.
• Figure 88 shows a locking post secure in the post slot.
• Figure 89 shows a rotated view of the locking post secure in the post slot.
• Figure 92 shows a view of the modular array with the capacitor wall section in position.
• Figure 93A shows the body of a magnetic securing post.
• Figure 93B shows an exploded view of a magnetic securing post.
• Figure 93C shows a magnetic securing post with the locking magnet.
• Figure 95A shows a magnetic insertion tool.
• Figure 95B shows the magnetic securing post slid into position on the magnetic insertion tool.
• Figure 95C shows another view of the magnetic securing post on a magnetic insertion tool.
• Figure 96 shows a cropped view of the cross section of an -A- & -B- junction and the insertion tool with a magnetic securing post loaded on it.
• Figure 97 shows a small steel retaining disk and a steel recess in the post slot.
• Figure 98 shows the small steel retaining disk bonded in the steel recess.
• Figure 102 shows the cathode contact side of a capacitor cell.
• Figure 103 A shows the anode contact side of a capacitor cell.
• Figure 103B shows a rotated capacitor cell.
• Figure 104A shows an insulated cover sectioned to reveal a honeycomb anode, an LED and a cathode LED channel.
• Figure 104B is a cropped, close-up view of the sectioned, insulated cover.
• Figure 104C shows an exploded view of a capacitor cell.
• Figure 104D shows a cropped, detailed area of a section of the insulated cover and honeycomb anode.
• Figure 104E shows the insulated cover with the anode conductive posts showing through the capacitor cover holes.
• Figure 105 A shows an insulated cover separated from a honeycomb anode.
• Figure 105B shows the reverse side of the insulated cover joined with a honeycomb anode.
• Figure 105C is a section view of an LED and the cathode LED channel.
• Figure 105D is a section view of tapered cover bosses on an insulated cover.
• Figure 105F shows the honeycomb anode separated from the insulated cover.
• Figure 105G is shows the LED in the exploded view of Figure 105F.
• Figure 106 shows the indicator LED.
• Figure 107A shows a capacitor cell casing and a honeycomb cathode.
• Figure 107B shows the capacitor cell casing and the honeycomb cathode separated.
• Figure 107C shows a cropped detail of a cathode conductive post.
• Figure 107D shows a partially assembled capacitor cell.
• Figure 155 shows a robotic 3D printing system.
• Figure 156 shows detail of an exploded view of a robotic arm and extruder.
• Figure 160 introduces a thermoplastic sheet into the vacuum forming setup.
• Figure 172 shows a close-up of an exploded view of a sectioned Wall Socket assembly.
• Figure 173 shows a close-up of a sectioned Wall Socket assembly aligned with a Pyramid Wall.
• Figure 175 removes the sectioning from the close-up.
• Figure 176 shows a cropped, exploded view of a full Pyramid Wall section, Wall Sockets and Aligning Template.
• Figure 177 removes the Pyramid Wall section and shows a close-up.
• Figure 178 shows an exploded view of Cross Panels with post for stacking "Flower” panels or “Petals” into a cell.
• Figure 179 adds a second level of panels to the assembly.
• Figure 180 shows an exploded view of the Flower Post.
• Figure 181 shows a section view of the Flower Post.
• Figure 182 details a section view of the Flower Post Cap, its snap fits and the snap fit sockets in the post.
• Figure 183 shows the first level of internal wiring in the Flower Post as it connects to the hinges, as well as the serial connection to the other levels of panels.
• Figure 187 shows the Cross Panels folded into a pyramid shape, making a complete
• Figure 188 shows an alternate stacking setup with a horizontal panel and Post connections.
• Figure 189 shows a section view of a completed stacking of horizontal panels, with the Cross Panels in the flattened position.
• Figure 190 removes the section view of the stacked panels.
• Figure 191 shows an alternate section view of the stacked, horizontal panels and the cross panels folded up into a pyramid shape.
• Figure 192 shows a completely assembled and folded Horizontal Flower Panel Cell.
• Figure 193 shows a section view of a concave, transparent cover over a panel section containing a horizontal flower petal assembly.
• Figure 194 shows variations of transparent cover geometries including flat, spherically concave, oval concave and teardrop concave.
• Figure 196 shows an alternate horizontal petal cell without a center post, one panel and hinge removed for viewing and a spherically concave transparent cover overhead.
• Figure 201 shows an exploded view of a supercapacitor cell.
• Figure 202 shows the positive and negative leads in the cell.
• Figure 203 shows a connection rack connected to the leads and a sectioned cell casing.
• Figure 204 shows the introduction of positive, honeycomb layers.
• Figure 205 shows all positive layers.
• Figure 212 shows an exploded views of the trailer frame, top and side Pyramid Wall sections and details of the wall section's front and back.
• Figure 214 shows an exploded view of the top and side transparent, dimpled covers.
• Figure 215 shows an exploded view of the top transparent dimpled cover.
• Figure 216 shows a section view of the trailer.
• Figure 221 shows a sound wall section with a breakaway view, exposing a foam or pellet filled interior.
• Figure 222 shows a stretch of sound wall barrier.
• Figure 223 shows a Pyramid Structure.
• Figure 224 shows an exploded view of one triangular sidewall of a Pyramid Structure.
• Figure 226 shows a completed triangular sidewall from another angle, ready to be inserted in base slots and onto a base.
• Figure 227 shows two views of a completed triangular sidewall engaged in base slots and ready to be connected to a base.
• Figure 228 shows one triangular sidewall inserted into a completed base section, with frame members in position.
• Figure 229 shows a completed Pyramid Structure with a cap to be inserted.
• Figure 230 shows a building with sides covered by Pyramid Wall sections and Pyramid
• Figure 231 shows partly assembled Pyramid Wall Structures on the roof.
• Figure 232 shows a building with Pyramid Wall sections on its sides and four Pyramid Wall Structures on its roof.
• Figure 233 shows a self-contained Pyramid Structure on a two-axis tracking system.
• Figure 234 shows an alternate building setup, with sides and roof covered with a single layer Pyramid Wall System.
• Figure 235 shows a cropped detail of a Wind Skirt surrounding a Pyramid Wall Section.
• the non-limiting embodiment shown in the figures demonstrate a sequence of manufacturing and assembly steps involved in making diamond wall sections.
• Various elements of this embodiment may be described with specific measurements. In other embodiments, the dimensions of the elements may be adjusted accordingly, for example, to produce smaller or larger diamond wall sections.
• the sequence of manufacturing and assembly steps may be reordered and various steps may be combined and/or omitted.
• the pyramid shape has many benefits including strength and increased surface area.
• One main idea behind the pyramid wall system is threefold: 1) to create a lightweight, inexpensive, modular system that is self-sustaining with power.
• the exposed inside/out pyramid pattern reduces wind resistance on the sidewalls of tractor-trailers, similar to the idea of dimples on a golf ball used to extend flight.
• the reduced drag alone can save at least 11% annual fuel costs per vehicle.
• the pyramid wall system is adaptable to structural frameworks that form many different geometric shapes (polyhedral) including, but not limited to, tetrahedrons (pyramids with 3 sides and a base), right pyramids (4 sides and a base), cubes, rectangular cuboids, etc. Wall sections may be sectioned further to form the boundary edge of a frame to support each face of the structure.
• the pyramid mold core 100 shown in Figure 01 is the underlying form used to produce the carbon fiber housing. It may be 3D printed in thermoplastic using a process called Fused Filament Fabrication (FFF), also called Fused Deposition Modelling (FDM).
• FFF Fused Filament Fabrication
• FDM Fused Deposition Modelling
• plastic filament is fed into an extruder which melts and feeds it through a nozzle.
• the filament may have composite fibers added as well for additional strength and dimensional stability.
• Data from a 3D model is converted into code which determines the path of the extruder head, the speed of the path, flow rate of material and temperature.
• the extruder head is attached to a dual gantry setup, allowing servo motors to position it over a level build plate at various points along the X, Y & Z axis. There may be two or more extruder heads, each controlled independently.
• the pyramid mold core 100 may be partially hollow with a laticed interior, or solid filled and/or electroplated for rigidity.
• The“foot print” 110 of the housing is diamond shaped, just under 29” x 18” diagonally and 2” thick. It supports four sets of pyramid shaped bosses 120 which are just under 5” high from each base to their apices.
• the entire mold core 100 can be made in one piece.
• Figure 02 shows a carbon fiber sheet 200 used to make the housing.
• Carbon fiber or its equivalent has several advantages over conventional materials and construction methods. It is lighter, stronger and more durable than wood or metal and can be formed into shapes not possible with these materials. It may be between 1 mm and 1.75 mm thick.
• the carbon fiber sheet 200 may be cut into a patern based on where the seams are to be located and/or to provide openings when positioned.
• the carbon fiber sheet 200 is vacuum formed to take on the shape of the pyramid mold core 100.
• Figure 04 shows a male conductive frame 400.
• This frame 400 creates a wireless unit and reduces the chance of long term damage by being embedded in the composite housing.
• This frame 400 referred to as a male -A- conductive frame, follows the contour of the pyramid walls.
• the frame 400 is 3D printed with dual materials; the first being an insulative thermoplastic which forms the outer shell (500), as well as the first and second insulative layers (which alternate between the conductive layers).
• the second material may be conductive, such as a graphene infused thermoplastic as one non-limiting example. It forms the first and second conductive layers as well as the“bird bone” core 1300, a hollow light weight internal structure to allow airflow.
• This bird bone core 1300 is a structural component providing increased strength at a fraction of the weight.
• the bird bone core 1300 also provides airflow (e.g., an inert gas flow) which allows a positive ionic current as low pressure gas flows through the lattice increasing current flow.
• airflow e.g., an inert gas flow
• the bird bone core 1300 also provides a conductive path for sections with solar panels 1800.
• the outer shell 500 has post slots 510 along the top face to allow locking posts 1660 to connect the diamond sections. This design may be used where space between back to back wall sections is restricted.
• post/slot combinations can be part of the outer shell 500 when space is not as restricted.
• Post slots 510 would be replaced with a raised cylindrical post that has a blind channel cut into the side.
• the profile of the channel has a“T” shaped cross section with a radiused inner face.
• Locking posts 1660 may be replaced with shouldered cylindrical bosses to create a“T” shaped post to fit inside these channels. (See Figures 36-39, 85, 87 & 88 for original locking posts 1660).
• Figure 06 shows the outer shell section 600 having half of the“V” profile of this cross section.
• the ball socket bosses 540 and ball socket snap fits 700 are shown. They may be made of an insulative thermoplastic.
• Figure 07 shows details of one of the ball socket snap fits 700 used to secure the ball joints 2150 of the panel rack plugs (see Figure 61). They have a spherical cavity with three relief slots to help conform to the ball shaped plug and then engage the ball shaped plug when in place.
• Figure 08 shows the first insulative layer 800 which is the same material as the outer shell. It can be differentiated because it follows the contour of the first conductive layer (see Figure 9). In this non-limiting embodiment, the material is approximately 1/32” thick.
• Figure 09 shows the first conductive layer 900 which may be printed with a graphene infused/embedded thermoplastic (or equivalent).
• This layer 900 conducts a negative charge, terminates with a conical shaped receptacle 1000 and may be approximately 1/32” thick in this non-limiting embodiment.
• the second insulative layer 1100 shown in Figure 11, is the same material as the outer shell 600 and the first insulative layer 800. This second insulative layer 1100 is sandwiched between the first and second conductive layers 900, 1200 and, in this non-limiting embodiment, is approximately 1/32” thick.
• Figure 12 shows the second conductive layer 1200.
• This layer 1200 is the same material as the first conductive layer 900 except that it conducts a positive charge and terminates with a conical shaped receptacle 1210. It can be considered a shell of the“bird bone” core 1300 (shown in Figure 13) but is distinguished because it follows the contour of the second insulative layer 1100.
• the second conductive layer 1200 is approximately 1/32” thick.
• the bird bone section 1300 of Figure 13 is also the same material as the first and second conductive layers 900, 1200 and carries a positive charge.
• the shape of this core 1300 can be hollow and organic, like a bird bone in order to be lightweight and to offer some structural reinforcement while allowing airflow.
• Figure 14 shows an alternate cross section of the layers of the frame in an end view. Starting at the center 1400, the“bird bone” 1300 is positively charged, surrounding the center 1400 is the second conductive layer 1200 (positively charged), then the second insulative layer 1100, then the first conductive layer 900 (negatively charged), then the first insulative layer 800 and finally the shell 600 on the outside. Post slots 510 are shown at the top of the image. (Note that in this example, the second insulative layer 1100 is not continuous, for example, due to limited space).
• Figure 15 shows a cropped view of a male -A- conductive frame 400, with open rectangular slots 550 at the comers. These slots are openings in the conductive“bird bone” core 1300 to allow the flow of low pressure gas between panel sections when they are connected.
• Figure 16 shows an isolated view of the connector tabs 560 for the first conductive layer 900. The outer border of this layer and these tabs is the first insulative layer 800.
• Figure 17 shows an isolated view of the connector tabs 570 for the second conductive layer 1200. The outer border of this layer and these tabs is the second insulative layer 1100.
• Figure 18 shows a male -A-conductive frame 400 in position on a vacuum formed, carbon fiber sheet 200.
• Figure 19 shows one set of three“keyhole” slots 1500 cut into the first layer of a vacuum formed, carbon fiber sheet 200.
• Figure 20 shows a detail of the profiles of the “keyhole” slots 1500. The narrow section of each slot 1500 retains the shoulder of a post 1810 on the back of a solar panel 1800, when it is put in position.
• Figure 21 shows the outside edges of the carbon fiber sheet 200 preparing to wrap around the frame 400 and on top of itself.
• Figure 22 shows the outside edges of the carbon fiber sheet 200 pulled up, exposing the“foot print” 110 of the housing to allow clearance for the clamp fixture 1600.
• FIG 23 shows two vents 1700 being cut into the carbon fiber sheet 200 at the long diagonal comer (opposite comer obscured in this view). These cuts are to allow clearance for the open rectangular slots 550, the connector tabs 560 & 570.
• Figure 24 shows a detail of the vents 1700.
• Figure 25 introduces the clamp base 1610 and Figure 26 introduces four slide action slides 1620 and Figure 27 shows the slide action slides 1620 positioned on the clamp base 1610.
• Figure 28 shows the inline clamps 1630 in position on the clamp base 1610.
• Figure 29 introduces the inline clamp hardware 1640.
• One of the four clamps has the hardware already in position.
• Figure 30 shows the clamp fixture 1600 in position with handles down and open.
• Figure 31 shows the inline clamps 1630 with handles up, closing against the slide action slides 1620.
• Figure 32 shows a detail of the clamping action against the carbon fiber sheet 200 into a V shaped boss 520 on the male -A- conductive frame 400.
• Figure 33 shows a close-up detail of the area affected by the clamping action including the carbon fiber sheet 200 and the V shaped boss 520.
• Figure 34 shows a close-up detail of the area where the carbon fiber sheet 200 wraps over the top of the male conductive frame 400 and back onto itself in a second layer.
• Figure 35 shows the carbon fiber sheet 200 completely wrapped over itself completing the second layer.
• Figure 36 shows circular cutouts 1650 into the top layer of the carbon fiber sheet 200, but not into the first layer. This is to create a recess for the locking posts 1660 to be bonded in.
• Figure 37 introduces a locking post 1660.
• Figure 38 reveals the bottom side of a locking post 1660. These four faces 1670 and/or the exposed faces of the circular cutouts 1650 have glue applied there to bond the posts 1660.
• Figure 39 shows all four locking posts 1660 in position.
• Figure 40 shows the wrap trimmed to expose the post slots 510 and Figure 41 shows the wrap trimmed to expose ball socket bosses 540 with ball socket snap fits 700.
• Figure 42 shows one set of three oval slots 1820 cut into the second layer of a vacuum formed, carbon fiber sheet 200.
• Figure 43 shows a detail of the profile of the oval slots 1820 on top of the“keyhole” slots 1500. These slots 1820 are aligned with the“keyhole” slots 1500 on the first layer and provide a stop against the head of a post 1810 on the back of a solar panel 1800 when it is put in position. There are four sets of slots 1820, 1500 for each pyramid boss 120 and a total of four pyramid bosses 120 for each carbon fiber housing.
• Figure 44 shows a complete male side wall 1900 (minus solar panels) and V shaped bosses 520.
• Figure 45 shows the male side wall 1900 (minus solar panels) oriented to show the V shaped grooves 530.
• Figure 46 shows the top side (inside) of a male side wall 1900 (minus solar panels) before the insertion of solar panels 1800.
• Figure 47 shows a single solar panel 1800 prepared to be inserted into a male side wall 1900 with a cutaway of the face it is sliding into and an adjacent face.
• Figure 48 shows the cutaway view in Figure 47 but along the long, diagonal edge (normal to a plane that bisects the short diagonal edges).
• Figure 49 shows the single solar panel 1800 in place into a male side wall 1900 with the same cutaway view as in Figure 48.
• Figure 50 shows a cropped detail of a cutaway of two solar panel posts 1810 with one post 1810 inserted at the wide section of a“key way” slot 1500 and its shoulder resting at one end of an oval slot 1820.
• Figure 51 shows a solar panel post 1810 locked in position with its shoulder on top of the narrow section of a“key way” slot 1500 and pushed against the opposite end of an oval slot 1820.
• Figure 52 shows a detail of both posts 1810, as well as a reinforcement tab 1830 on the back of a solar panel 1800 locked in position.
• Figure 53 shows a module 2000 of four (4) solar panels 1800 in relative position and Figure 54 shows a solar panel module 2000 locked in place in a male side wall 1900.
• Figure 55 shows a connection rack 2100 used to join a solar panel module 2000 and connect it to the first conductive layer 900 and the second conductive layer 1200.
• These racks 2100 are beneficial because they eliminate exposed wires and, if damaged, can be easily replaced. Because they are arranged in parallel, individual racks 2100 can be replaced without interrupting current flow.
• Figure 56A shows a cutaway view of a connection rack 2100. It shows its connection rack body 2110, solar rack positive circuit 2120, solar rack negative circuit 2130, positive lead 2160 and negative lead 2170.
• Figure 56B shows two views of the extracted circuits for clarity. They are solar rack positive circuit 2120 and positive lead 2160, in the left view, and, in the right view, solar rack negative circuit 2130 and negative lead 2170.
• connection rack 2100 will consist of metal conductive circuits 2120, 2130 overmolded with a thermoplastic body.
• the components may be 3D printed with dual extruder heads.
• the body 2110 is printed using an insulative thermoplastic, while a second material will make the conductive circuits 2120, 2130, possibly using a graphene infused thermoplastic similar to the male conductive frame 400.
• the body 2110 is 3D printed or molded in sections and locks in conductive wire.
• Figure 57 shows a connection rack 2100 oriented to join a male side wall 1900.
• Figure 58 shows the connection rack 2100 locked in place with the male side wall 1900.
• Figure 59 shows a cutaway detail of one of the eight (8) detent sockets 2190 on a connection rack 2100.
• the detent sockets 2190 are used to retain the bulbous tip of the conductive lead on the solar panel post 1810. In this image, the solar panel 1800 and its post 1810 are hidden to reveal the cavity of the detent socket 2190.
• Figure 60 shows a cutaway detail (similar to Figure 59), where the bulbous tip of a conductive lead on the solar panel post 1810 is exposed as it is locked into a detent socket 2130.
• Figure 61 shows a cutaway of a connection rack 2100. At the bottom is a detail of the ball joints 2150 that go into the ball socket snap fits 700 (see Figure 7). These snap fits 700 house the exposed positive lead 2160 of the solar rack positive circuit 2120 as well as the exposed negative lead 2170 of the solar rack negative circuit 2130.
• Figure 63 shows a view (similar to Figure 60), but reveals the ball joints 2150 locked into the ball snap fits 700 and a cutaway of the connection rack 2100 exposing a solar panel post 1810 in place .
• Figure 64 introduces the three (3) remaining connection racks 2100 to complete the backside of a solar panel section.
• Figure 65 shows all four (4) connection racks 2100 locked into place.
• Figure 66 shows a second module of four (4) solar panels 2000 separated and ready to be locked into place.
• Figure 67 shows the second module of four (4) solar panels 2000 locked into place.
• Figure 68 shows a completed assembly of a male solar panel section 2300 from the exposed solar panels side.
• FIG 69 shows a solar panel 1800 and the area to be detailed of a transparent casing 1840 (which is shown in Figure 70).
• This casing consists of wave patterned, refraction steps on the outside surface of the panel 1800.
• the cells on the photovoltaic (PV) solar panel 1800 are 3D printed with multiple extruder heads, each assigned a different material.
• the first extruder prints an insulative backing.
• a second prints a conductive path for the bottom positive cell layer using conductive ink.
• a third prints a positively“doped” semi-conductive layer and a fourth prints a negatively doped semi-conductive layer.
• the second extruder can be reintroduced and prints a conductive path for the top negative layer.
• Figure 119 shows pyramid frame comers 3420 added to the frame as a cosmetic shield to missing quarter panels.
• Wiring layers may be produced with any combination described herein and stacked for multiple sets of panels.
• the mounting post body may be extended with slots added to allow for the stacking of multiple panel arrays.
• Panels transparent to visible light (or specific wavelengths) may be stacked within the pyramid space, each layer positioned to absorb a specified range of wavelengths.
• Panel layers may be flat and parallel to each other or flat and independently oriented/angled/positioned to each other.
• Panel layers may be curved to form any geometric or non-geometric shape. They may be concentrically nested or independently oriented/angled/positioned to each other. They may be staggered and offset, like the petals of a rose. If panels have opaque edge contacts, they may only extend part way along the sides and avoid the top so as not to obscure panels underneath. Otherwise, transparent contacts may be used along the perimeter of the panel.
• FIG 139 highlights slots 4660 in the mounting post body 4650. Additional panels 4570 are positioned to slide into place.
• a mounting post body 4650 is shown surrounded with exploded components. This body 4650 has several purposes: it connects all of the panels 4610, 4670 to a central location, houses the internal wiring and provides a countersink to fasten a panel assembly 4600 into an inverted pyramid cavity.
• the mounting hub 4530 Below the mounting post body 4650 is the mounting hub 4530, which will be positioned in the inverted pyramid cavity. External leads 4680 protrude from body 4650 just above the hub 4530.
• a mounting screw 4640 is just above the body 4650 and a protective access cap 4655 with snap fits 4656 is just over the screw.
• the protective access cap 4655 may have a generally pyramid shape and a reflective coating to reflect light back to the solar panels 4610, 4670.
• Figure 142 shows a transparent panel 4610 with a section view of its hinge 4620 and Figure 143 highlights a section view of the hinge 4620.
• the negative contact on a lead 4621 can connect to a socket in a mounting post body 4650, a positive contact on a lead 4622 can go into the body of the hinge 4620 and a positive lead contact 4623 connects to a panel lead.
• Figure 144 shows a detail of a cropped cross section, where a panel 4610 and its hinge 4620 are connected and positioned horizontally; its positive lead 4622 is inside a cavity in a mounting post body 4650.
• a second panel 4670 is also in position in the cavity in the mounting post body 4650, while two leads 4680 from the internal wiring are exposed.
• a mounting hub 4630 is ready to be put in place.
• Figure 147 introduces the second layer of wiring 4682 to connect to the second layer of panels and electrical leads 4680. These wiring layers may be stacked for multiple sets of panels.
• Figure 148 shows hinges in the folded position exposing the negative and positive leads 4680 which will connect through the mounting hub.
• Figure 149 shows three back panels 4610 in the flat position, a fourth back panel 4611 folded up exposing its backside which in one non-limiting embodiment, may be coated with electroluminescent paint, electroluminescent tape or LEDs for night time use. These panels are transparent or semi-transparent to visible light.
• the backside also has snap fits 4612 to help secure the panels 4610, 4611 in the inverted pyramid housing, which in one non-limiting embodiment, has its inside faces coated with electroluminescent paint, electroluminescent tape or LEDs. Also shown is the second layer of panels 4670.
• Figure 150 shows a transparent panel 4610 and its latice of contacts.
• these contacts are honeycomb shaped, to increase contact surface area and efficiency.
• the panels 4610 and its contacts may be made with conventional manufacturing methods, 3D printed with conductive material or a combination of the two.
• Figure 151 highlights a cropped detail of a panel 4610, highlighting its honeycomb latice 4613 of contacts. Its positive edge contact 4614 and positive hinge socket 4617 are shown. Also shown is its negative edge contact 4615 and negative hinge socket 4616.
• Pyramid Wall sections may also be made through additive manufacturing, also known as additive manufacturing
• 3D printing may be made in part or in full with specific 3D printing methods such as Fused Filament Fabrication (FFF), Fused Deposition Modeling (FDM), Stereolithography (SLA), Selective Laser Sintering (SLS) and Direct Metal Laser Sintering (DMLS).
• FFF Fused Filament Fabrication
• FDM Fused Deposition Modeling
• SLA Stereolithography
• SLS Selective Laser Sintering
• DMLS Direct Metal Laser Sintering
• a process which cures SLA resin with oxygen and UV light increases print speed up 25X to 100X. This ultrafast additive method is geared toward full production.
• Robot arms may travel on a conventional linear rail or linear gantry system or move autonomously. Robotic arms may travel in a curvilinear motion on a simple curved track, a compound curve track or a three dimensionally curved path. Robotic arms may work as individual units or as multiple arms moving in unison or independently.
• the Pyramid Wall System may be FFF/FDM 3D printed in part or in full by extruders on robotic arms, incorporating conventional FFF/FDM or other production methods. Combinations of conventional FFF 3D printing and robotic 3D printing can be used when using multiple materials and extruder diameters. These options allow large volume prints made with large diameter extruders and to have detailed features made with smaller diameter heads.
• Figure 154 shows a flexible screw conveyor 4700 for handling pelletized plastic for use in robotic 3D printing. It labels the following: a control panel 4710 for the system, a stand 4720, conduits 4730 and an electric motor 4740. A feeder 4750 is shown (to be connected via hose to one of the 3D printer’s extruders). Also shown is a flexible screw enclosure 4760 and a cutaway view of the flexible screw 4770. This screw 4770 draws pellets up to the feeder 4750.
• Pelletized plastic 4780 is shown feeding into the flexible screw enclosure 4760 which is attached to the main hopper 4790. This hopper 4790 stores material to print and has its hinged hopper door 4785 removed for clarity.
• Figure 156 shows detail of a cropped section of an exploded view of a robotic arm 4830 and extruder.
• molds or forms for composite wrapping may be 3D printed using additive manufacturing processes such as FFF or FDM. They may also be made through SLA, SLS or DMLS. As described above, the pyramid mold core 100 can be made through 3D printing processes such as Fused Filament Fabrication (FFF) or Fused Deposition Modeling (FDM). Molds may be made with a CNC milling machine or router. Molds may also be made by pouring a variety of material (including but not limited to plastic and concrete) between back-to-back wall sections.
• FFF Fused Filament Fabrication
• FDM Fused Deposition Modeling
• Pyramid Wall sections may be made from Vacuum formed thermoplastic sheets. Pyramid Wall sections may also be injection molded, rotomolded, cast, and/or extruded. Wall sections may be made flat through any of the above processes (e.g., additive manufacturing or molding) to be stacked for storage and transportation. The sections can then be deployed into shape manually by incorporating a living hinge. Or they may take final form over a mold shape. They may also take form in a“4D” process by using an outside stimulus such as heat, electricity or a chemical reaction.
• Substitute materials for composite mold wrapping include: fiberglass and Kevlar.
• Substitute material for FFF/FDM 3D printing includes fiberglass and Kevlar (strands or chopped), thermoplastics (by themselves), concrete, cement, wood pulp, composite wood with binder, and recyclables. These materials can be fed as pellets, filaments or combinations thereof and extruded through the 3D printer nozzle.
• Substitute materials for various mold process include: wood pulp/composite wood, recyclable material (including plastic) and composite embedded thermoplastics, cement or concrete.
• Walls may be milled or routed out of plastic or wood; made out of sheet metal; or stamped into shape.
• any of the components in the Pyramid Wall System may be completely manufactured with any of the processes described herein or in a combination of such processes.
• a vacuum/thermoforming setup 4900 is shown.
• a form 4910 shaped as the inside faces of the inverted pyramids in a wall panel section has a network of vacuum tubing 4920 attached to its backside.
• Figure 158 shows the setup 4900 including the top of the form 4910, a network of vacuum tubing 4920, a section of the tubing and a section of the form 4910 showing where the vents connect to the vacuum path.
• Figure 159 shows a detail of this section view with the form 4910, vacuum tubing 4920, sectioned vent hole 4930 and a section of vacuum tubing aligned with vent holes in the form 4910.
• Figure 160 shows the thermoforming setup 4900 with a heated thermoplastic sheet 4945 above it.
• Figure 161 shows a pyramid array 4950 formed from a thermoplastic sheet and removed from the form 4900.
• Figure 162 shows an exploded view of a thermoformed pyramid wall 4990, and its components. At the bottom is the pyramid array 4950. Above that is the array’s support frame core 4960 (dummy or with bird-bone and conductive/insulative layers), the support frame’s top with sockets 4970 and mounting plugs 4980.
• Figure 163 shows the back side of a completed wall section 4990.
• Figure 164 shows the front side of that wall section and the inside face of the thermoformed pyramid array 4950.
• a conventional injection mold 5000 (without side action) is used to create a complete wall section.
• a section view of the molten plastic channels is shown starting with the sprue 5010 and the runners 5020 which extend the entire length of the mold. The runners are then connected to gates 5030 which terminate at points in the mold core 5040 (in a similar orientation to the vents 4930 in the thermoforming images such as in Figure 159).
• Plastic can then be allowed to flow from the gates into mold cavity 5050 while top support plate 5060 and bottom support plate 5070 keep the mold 5000 closed.
• Figure 166 a completed wall section 5100 is shown ejected from the mold, with the mold core 5040, top support plate 5060, mold cavity 5050 and bottom support plate 5070 shown open.
• Figure 167 shows the back side of a single part wall section 5100 with completely molded features. In another embodiment, any of the features on the molded part may be removed, with the entire wall section assembled from multiple parts.
• standalone wall sections can be connected back to back with fasteners.
• the axis of the posts and sockets may be aligned as posts are fit into sockets to be secured.
• sockets may have semi-circular cutouts so that posts may slide in.
• These standalone sections have space which can be filled with closed cell foam or pellets of a variety of material (including recycled plastic or paper) or cement. This filler material may be used for thermal insulation, sound absorption or both.
• a lattice can be inserted between sections and reinforced with material such as closed cell foam. The lattice may be made through conventional manufacturing methods including additive manufacturing, also known as 3D printing.
• Figure 168 shows two wall sections back to back and separated, in position to form a standalone pyramid wall sandwich 5200.
• Figure 169 shows cropped section of a wall sandwich 5200 showing back to back sections in position and pyramid arrays 4950. Detail of that section includes a socket 4970 on one side with a drainage port 4975. A plug 4980 is shown opposite the socket with a drainage port 4985 in line with the port on the socket. The drainage port can be used for water, moisture and as a vent for heat.
• Figure 170 shows a breakaway view of the standalone pyramid wall sandwich 5200.
• closed cell foam 5210 is shown partially filling the cavity between wall sections.
• solar panel connection racks 2100 connect each of the four sets of four panels into one socket in the frame.
• capacitor/battery connection racks 3200 connect each battery/capacitor in the same fashion
• An altemate/supplemental connection method for a single sided Pyramid Wall section is to have their center posts form an electrical hub which connects the solar panel leads. This hub then connects into a cavity in a Wall Socket which has been mounted onto a wall or support surface. A fastener protrudes from the hub which is secured into an embedded, threaded insert in the Wall Socket cavity. The cavity has electrical contacts which then draw power from the hub and transfer it to a wiring harness or electrical conduits in an Aligning/Mounting Template/Fixture. Cutout sections in the Aligning/Mounting Template/Fixture can have the same profile as a Wall Socket. Notches in the cutout sections provide relief for contact nipples in the Wall Sockets.
• the Aligning/Mounting Template/Fixture may also be used as a temporary mounting template to align the wall sockets before they’re fastened or bonded into a wall.
• the template would have no electrical conduits or embedded wiring. It could be for Wall Socket alignment and then be removed.
• the Aligning/Mounting Template/Fixture may or may not include electrical conduits or embedded wiring. It may be completely supported by sockets after they are fastened or bonded into a wall.
• the Aligning/Mounting Template/Fixture may be fastened or bonded independently to provide additional support for the Pyramid Wall Section.
• the Wall Sockets and Aligning/Mounting Template/Fixture may be machined, routed, laser cut, water cut or molded through various methods including injection molding. They may be formed through additive manufacturing, also known as 3D printing. They may be made in part or in full with specific 3D printing methods such as Fused Filament Fabrication (FFF), Fused Deposition Modeling (FDM), Stereolithography (SLA), Selective Laser Sintering (SLS) and Direct Metal Laser Sintering (DMLS). Electrical contacts in the Wall Sockets and conduits in the Aligning/Mounting Template/Fixture may be over-molded wires, 3D printed with conductive material, or a path for insulated wiring. The conduits may be coated with superconductive material such as Graphene or equivalent and/or filled with superconductive gel or any combination thereof.
• FFF Fused Filament Fabrication
• FDM Fused Deposition Modeling
• SLA Stereolithography
• SLS Selective Laser Sintering
• DMLS Direct Metal Laser Sinter
• the Wall Sockets and Aligning/Mounting Template as a permanent fixture may have mounting holes to allow fastening to a mounting surface.
• the Wall Sockets and Aligning/Mounting Template may be secured with fasteners (such as screws); a bonding compound or a combination thereof.
• a single, diamond Pyramid Wall section 4900 is shown above a Wall Socket 5300 and an Aligning/Mounting Template/Fixture 5400.
• the Template 5400 can be used to temporarily position Wall Sockets 5300 as they’re secured onto walls, roofs or other surfaces with fasteners or bonding compounds.
• the Template 5400 is permanently secured for reinforcement and/or to provide an electrically conductive path between panel sections, capacitors and/or batteries.
• Figure 172 shows a detail of an exploded view of a Wall Socket 5300 sectioned. It shows a Socket body 5310 with nipples for electrical leads 5315. It is sectioned to show the counter-bore for a Pyramid Wall post, a drainage area in the counter-bore 5316 and a thru hole for a brass threaded insert 5320. The drainage area allows moisture to escape and heat to vent.
• the insert 5320 is aligned to accept a screw 4640 and secure the Pyramid Wall post, which houses a solar panel assembly.
• concreate screws 5330 (for example, Tapcon screws used to secure fixtures to concrete) will be used to secure the Wall Socket to a wall or roof.
• Figure 173 introduces the post of a Pyramid Wall section into the Wall Socket image.
• a solar panel lead 4680 from a panel array in the Pyramid Wall section is aligned with a conduit 5340 in the Wall Socket.
• Figure 174 adds a detailed section of an Aligning/Mounting Template/Fixture.
• its conduit 5410 is exposed and aligned with the Wall socket conduit and the solar panel lead.
• This conduit 5410 may be a path for insulated wiring, over-molded wires or 3D printed conductive material.
• the conduits 5410 may be coated with superconductive material such as Graphene or equivalent and/or filled with superconductive gel or any combination thereof.
• Figure 175 shows a section of a completed Pyramid Wall System 4990 as it connects into a Wall-Socket 5310.
• the Aligning/Mounting Template/Fixture 5400 aligns each Wall Socket and can either be removed after being an alignment tool or permanently fixed with electrical conduits.
• Figure 176 shows detail of an exploded view of a Pyramid Wall 4990, some Wall Sockets 5300 and an Aligning/Mounting Template/Fixture 5400.
• Figure 177 Removes the Pyramid Wall and shows a close-up of the image.
• Wall Sockets 5300 are in position to be fit into the receiving cavities of an Aligning/Mounting Template/Fixture 5400.
• Mounting holes 5420 may be used to secure the mounting template onto a surface. The holes may be left as is or modified with countersunk holes for fasteners.
• the Pyramid Wall System can take advantage of space within the pyramid space to position layers of semitransparent or transparent cells/panels to absorb specified wavelengths of visible and/or non-visible light. This is shown in Figure 139 and highlighted in Figures 142, 150, 151 and 152, where a second layer of“transparent” cells is introduced.
• the first layer of solar panels may be single sided or bifacial and fastened to the inside faces of the pyramid housing. They may use graphene or equivalent superconductive material to create transparent nanowires or to coat conventional electrical contacts. Panel contacts may be arranged in a dense geometric pattern such as (but not limited to) a honeycomb shape, to increase contact surface area and efficiency.
• Both the first and subsequent panel layers may be transparent in the visible spectrum and made of inorganic materials such as perovskite or organic salts. They can be stacked like petals of a flower around a post or“stem”. The stacking may be flat and form the sides of offset pyramids around a stem or the sides may be curved and/or overlap like the petals of a rose. Panel layers may be flat and parallel to each other or flat and independently oriented/angled/positioned to each other. Panel layers may be curved to form any geometric or non-geometric shape. They may be concentrically nested or independently oriented/angled/positioned to each other. They may be staggered and offset, like the petals of a rose. Individual panels may be split into two or more sections and positioned independently. Panel layers may be coated with anti-reflective and/or polarizing compounds.
• the panels and its contacts may be made with conventional manufacturing methods, 3D printed with conductive material or a combination of the two.
• Solar panels may be secured in a mounting post which will allow a conductive path through a central location.
• the mounting post may be manufactured with conventional manufacturing methods such as injection molding or 3D printed in any of the various methods described above or combinations thereof.
• transparent superconductive capacitors can be used between transparent cell layers for storage.
• Figure 178 shows an exploded view of panels 4610 and their hinges 4620 around a Flower Post assembly 5600. These panels form a Cross Panel assembly similar to that shown in Figures 138-153, with the difference that the Flower Post assembly allows multiple sets of panels to be stacked.
• the Flower Post s Connection Hub 5610. This hub is used to stabilize and secure the panels in the Pyramid Wall cavities.
• Figure 179 introduces a 2nd layer of panels 4670.
• Figure 180 shows an exploded view of a Flower Post assembly 5600. It includes the post’s base or hub 5610, the post body 5620, a mounting fastener 5630 and an access cap 5640. In one non-limiting embodiment, it is used to mount the solar array into a pyramid wall section and into a wall socket. It may be coated for reflectivity and contain electrical paths or conduits which may be over-molded, inserted or 3D printed with electrical leads. It may have a different profile from the diamond shape shown, such as circular, oval or any regular or irregular polygon, it may taper and may be scaled differently to account for space restriction.
• Figure 181 shows a section view of the Flower Post 5600.
• the post’s hub 5610 is below the post body 5620 with a mounting fastener 5630 in place in the body’s countersunk hole.
• the access cap 5640 is directly over it.
• Figure 182 shows a close-up of features on a cropped section view of the post’s body
• Panel recesses 5622 along the outside of the post’s body 5620 position the different levels of panels.
• Snap fit sockets 5621 allow snap fits 5641 on the access cap 5640 to secure it in place and protect the fastener.
• Access cap recesses 5642 allow tool access for quick release.
• Figure 183 shows the lst level of wiring 5650 to connect to the Cross Panel hinges 4620. It follows the same circuit, variety of material and manufacturing processes as the wiring layers described for the Cross Panel in Figures 146-148. The exception is the serial connection 5651 to connect the multiple levels of panels in the cell.
• Figure 184 shows the negative and positive leads 5682 which will connect through the mounting hub.
• the 2nd level of wiring 5683 through the 7th layer of wiring 5688 is marked on one side only for clarity.
• Figure 185 shows a stacking from the 2nd level panels 4670 through the 7th level panels
• Figure 186 shows a completed, stacked Flower assembly 5700, with the Cross Panels 4610 in the flattened position, and the Flower Post’s hub 5610 exploded.
• Figure 187 shows a completed Flower assembly 5700, folded into a pyramid shape, its outside surfaces coated with electroluminescent paint, electroluminescent tape or light-emitting diodes (LED)s 4611. Panels may be transparent or semitransparent to different wavelengths depending on the requirements of the electroluminescent coating or LEDs.
• each panel may form a single, flat layer around the mounting post, where their exposed faces are parallel to the footprint of the pyramid.
• Each layer may be curved and concentrically nested around the mounting post.
• Each layer may be equally spaced or spaced differently along the mounting post.
• Each layer may be angled independently from each other or in any combination thereof.
• Panels may be coated with anti-reflective and/or polarizing compounds.
• Figure 188 introduces a lst layer horizontal panel 5800, who’s face is oriented parallel to the pyramid’s base or footprint.
• the edges of a clearance hole in the horizontal panel can be positioned just above the panel recesses 5622 in the flower post.
• Connecting tabs 5805 that fit into the recesses can be bonded or fastened to the lst layer horizontal panel. Subsequent panels may be assembled first, working toward the top.
• Figure 190 shows a completed Horizontal Stacking Flower 5900 with Cross Panels 4610 shown flat and lst layer horizontal panel 5800 highlighted.
• Figure 191 shows an alternate section view of the panels and the increased surface area from their configuration. It highlights the post’s hub 5610, the post’s body 5620, the mounting fastener 5630 and the access cap 5640.
• Figure 192 shows the horizontal stacking flower 5900 folded into a pyramid shape. Its outside surfaces 4611 are coated with electroluminescent paint, electroluminescent tape or LEDs.
• the stacking flower may be non-horizontal.
• transparent covers may be used for various purposes within the Pyramid Wall System. They may be used for protection from weather, to provide an aerodynamic surface and/or to aid in the collection or dispersion of light.
• the geometry of the covers may be flat, indented or protruding and be of varying shapes. They may cover individual cells, small panel sections or large arrays. They may be uniform or mixed depending on the application.
• Covers may be made from a number of different materials transparent to various wavelengths of visible and non-visible light. These include but are not limited to glass, transparent polymers, transparent inorganic polymers, transparent epoxy resin, transparent ceramics and combinations thereof. These materials may be treated with transparent silica coatings, transparent epoxy or transparent nano-coatings for protection.
• Covers forming a protective barrier for solar panels may also provide protection for structures in windy areas. They may reduce drag when used to shield solar panels on moving vehicles. Data from wind tunnel tests and computer analysis such as computational fluid dynamics (CFD) will determine the specific geometry of a cover segment, as well as the arrangement of these segments over a large array.
• CFD computational fluid dynamics
• the Pyramid Wall System may be exposed to extreme weather conditions, moisture and heat ventilation ports can be introduced in various components in the wall sections. They may include side walls, edges comers, posts and mounting sockets on the Pyramid Wall and comers and edges on the covers. Covers may perform a dual function as solar cells transparent in the visible spectrum and made of inorganic materials such as perovskite or organic salts. They may use graphene or equivalent superconductive material to create transparent nanowires or to coat conventional electrical contacts. Panel contacts may be arranged in a dense geometric pattern such as (but not limited to) a honeycomb shape, to increase contact surface area and efficiency (as described above).
• Covers may function as any type of conventional simple lens, lenticular lens or Fresnel lens. These lenses may be of a variety of shapes and have a variety of purposes including focusing, defocusing and redirecting light.
• Figure 69 in the original filing shows a wave shaped solar panel 1800.
• Figure 69 also highlights a sample area of this panel 1840.
• Figure 70 details this sampled area and shows a solar cell cover with gradient wave patterned, refraction steps.
• Covers may be coated with anti-reflective and/or or polarizing compounds.
• Covers may be made as individual units for individual pyramid cells. They may be made as small modular sections or complete panels. Modular sections or complete panels may have custom shaped areas to secure over individual pyramid cells with break-away features added for individual units. In this way, only damaged units need to be replaced.
• Covers may be made through conventional methods used for producing clear plastic sheets including extrusion, casting, blown film, injection molding and thermoforming. Breakaway sections may be designed as molded features or added with a secondary manufacturing process such as water jet cutting, laser trimming or cutting blades.
• Covers may also be made through additive manufacturing, also known as 3D printing. They may be made in part or in full with specific 3D printing methods such as Fused Filament Fabrication (FFF), Fused Deposition Modeling (FDM), Stereolithography (SLA), Selective Laser Sintering (SLS) and Direct Metal Laser Sintering (DMLS).
• FFF Fused Filament Fabrication
• FDM Fused Deposition Modeling
• SLA Stereolithography
• SLS Selective Laser Sintering
• DMLS Direct Metal Laser Sintering
• a process which cures SLA resin with oxygen and UV light increases print speed up 25X to 100X. This ultrafast additive method is geared toward full production (as described above).
• Breakaway sections in 3D printed parts may be made as a design feature using a single material. Breakaway sections may also be formed from the grooves/cavities created after the removal of 3D print support material. Alternatively, they may be added as a secondary manufacturing process such as water jet cutting, laser trimming or cutting blades. NOTE: This section shows examples of covers on horizontal petal setups, with and without posts. But they can be used in any of the solar panel variations, as well as combinations of capacitors and batteries.
• Figure 193 shows a section view of a spherical, concave cover 6010 and horizontal stacking flowers 5900.
• the access cap 5645 is truncated for clearance and the cover 6010 fits onto a 4-cell cavity in a wall section 4990.
• a center screw (not shown) may be used to secure the cover along with snap fit features in the comers.
• Figures 194 and 195 show variations of the cover in several non-limiting embodiments as examples for a single cell.
• a flat cover 6000 a spherically concave cover 6010, an oval concave cover 6020 and a teardrop concave cover 6030 are shown.
• a spherically concave cover with a lens 6040, a spherically convex cover 6050, an oval convex cover 6060 and a teardrop convex cover 6070 are shown.
• the lens feature is not limited to the spherically concave variation, nor to any of the variations in these figures.
• the lens shape may be any variation of conventional simple lens or Fresnel lens.
• the material for any of the covers may be an optically clear compound, transparent solar cells, transparent capacitors or any combination thereof.
• Panel layers may be coated with anti-reflective and/or or polarizing compounds.
• Comers of the panels may provide electrical contact through leads along the inside edges of the pyramid cell or the edges between the sides of folded cross panels.
• a simplified version of a truncated mounting post would draw current from the inside edge leads into a central location (not shown).
• Figure 196 shows an alternate version of the horizontal stacking flower 6100.
• the non post, stacking flower 6100 is shown with one cross panel 4610 and hinge 4620 removed to show various features.
• the backside of the cross panels 4610 may be coated with electroluminescent paint, electroluminescent tape or LEDs.
• six nested panels: 6110, 6120, 6130, 6140, 6150 and 6160 are shown press fit into the cross panel sides. Electrical contacts may be at the outer comers of the horizontal panels with the edges of the cross panels 4610 providing a serial connection.
• the cross panels may have groove features on the inside face to hold the horizontal panels when folded in place or they may be bonded (or a combination of the two).
• the panels may be flat or curved and may be positioned in various orientations within the pyramid cavity, not necessarily parallel to the footprint/base of the pyramid. Above the pyramid cavity is a spherically concave cover for reference.
• Figure 197 shows an exploded view of a truncated locking hub 6200.
• the hub base 6210 is similar to the hubs in the cross panel and other flower designs.
• the hub body 6220 has the same function as the cross panel and flower design posts. It provides a wiring path as in the other designs and support for the hinge contacts. But it is a much lower profile as it isn’t needed to support the flower petals.
• a mounting fastener 6230 is shown above the hub body, which has a countersunk through hole to position it. Electric leads 6250 from the wiring path are shown.
• Figure 199 shows the hub base and body removed and highlights the internal wiring of the truncated base 6240. Two hinge bodies are hidden to remove clutter from the image. The internal wiring leads 6250 are shown connected to the hinge contacts.
• Figure 200 shows a completely assembled horizontal flower panel assembly with a concave transparent cover 6300.
• supercapacitors are designed for quick charging, while batteries are designed to provide long- term energy.
• Supercapacitors also called“ultracapacitors”
• supercapacitors are lightweight and have a high power density, meaning they can charge and discharge over a range of a fraction of a second to minutes. They maintain high efficiency over many years, millions of cycles and a wide range of temperatures, but are expensive and have limited storage.
• batteries have high energy density, meaning they can charge and discharge over the course several minutes to several hours. They are less expensive and have more storage than supercapacitors.
• their cycle life is much shorter.
• their operating temperature is limited and they degrade quickly under heavy loads such as intermittent solar power. By shifting load spikes to supercapacitors, the life of the battery can be extended. And as supercapacitor storage increases, it will complement batteries in applications such as electric vehicles, speeding up charge times significantly.
• Capacitor storage is directly related to the surface area of their electrodes, so a dense stacking of honeycomb layers was introduced to increasing energy storage.
• the density of the layers within the supercapacitor and the number of layers may vary. These layers are coated with graphene, or equivalent nano-particles, creating additional surface area, which leads to higher storage capacity.
• the pattern of the electrodes may be an array of any geometry, not necessarily honeycomb. Also, the pattern on each layer may combine with the pattern on subsequent layers to make a specific 3D geometry to get more optimal surface area.
• the layers are not restricted to being parallel to the base/footprint of the pyramid. Nor are they restricted to being parallel to each other or flat. They may be curved.
• a superconductive gel electrolyte is introduced between the layers which increases energy density, extending discharge time to match that of batteries, see Figures 101-115.
• Additive Manufacturing also known as 3D printing
• the intricate geometries required for these supercapacitors were not easily possible or they were prohibitively expensive. As the speed of this process increases, parts can move directly from prototype to manufacturing, driving costs down further.
• FFF Fused Filament Fabrication
• FDM Fused Deposition Modeling
• SLA Stereolithography
• SLS Selective Laser Sintering
• DMLS Direct Metal Laser Sintering
• a process which cures SLA resin with oxygen and UV light increases print speed up 25X to 100X. This ultrafast additive method is geared toward full production.
• Supercapacitor layers may be made with chemically etched metal plates or foil to increase surface area/capacity.
• An alternate, hybrid configuration which combines supercapacitor layers and solar panel layers in a single pyramid cell may be used where there is space, weight and/or cost restrictions.
• the bottom section of the pyramid space would function as a capacitor, while the top would be for solar panels.
• Other non-limiting configurations may substitute batteries for capacitors in the same space.
• batteries may substitute or complement capacitor storage in any of the various embodiments.
• Figure 201 shows an exploded view of a supercapacitor cell 6400.
• the components include: cell cover 6410, honeycomb lattice pyramid 6420, supercapacitor casing 6430 and supercapacitor connection rack 6440. Similar components are shown in Figures 109 and 111 including a cover 3110, a shell or casing 3160 and connection rack 3200. Those components have a different geometry than those in Figure 201.
• Figure 202 isolates the following components: a positive serial post 6421, positive electrical leads 6422, a negative serial post 6423 and negative electrical leads 6424.
• the posts 6421 and 6423 provide a serial connection for each of the honeycomb layers, according to their charge.
• the positive leads 6422 and the negative leads 6424 connect into posts on the supercapacitor casing 6430 which snap fit into the supercapacitor connection rack 6440.
• Figure 203 shows a supercapacitor casing 6430 sectioned in half to reveal the negative electrical leads 6424 as they’re snap fit into the supercapacitor connection rack.
• the negative serial post 6423 is shown for reference.
• the rack has internal wiring to draw current into two of its own leads that snap fit into sockets on the pyramid wall body. These leads connect to the conductive elements in the bird-bone frame on the pyramid wall section.
• Figure 204 shows the introduction of positive honeycomb layers 6425.
• eleven positive layers 6425 are shown.
• eleven negative honeycomb layers 6426 are highlighted to show a complete honeycomb latice pyramid 6420. Angled top and botom views show detail in the latice pyramid 6420.
• Figure 207 shows a complete supercapacitor module 6500.
• the module is upside down and atached to an identical module.
• the opposite section may be a pyramid wall panel. This wall section may have multiple versions of solar panels in it.
• Figure 209 shows a section view of a complete supercapacitor module 6500.
• two honeycomb latice pyramids 6420 are shown.
• Connected at top is a pyramid wall housing with three configurations of solar panels.
• this cell in the pyramid wall housing has a spherically concave cover 6010 in one comer.
• Next to that is a“conventional” flower assembly 5700 and next to that is a hybrid supercapacitor/post-less flower panel cell 6600.
• Figure 210 shows the same complete supercapacitor module 6500 with a top cover sectioned.
• the modular cover contains at least one spherically concave cover 6010 and two flat covers 6000.
• cover styles may range from 6000 to 6070 or any geometric shape based on the application.
• the Pyramid Wall System has applications for both mobile installations and the trucking industry. Mobile setups may be deployed for emergency power or shelters in remote locations, their containers formed from Pyramid Wall sections that are hinged in one or more segments. They may unfold and track the Sun or form a fixed structure. Within the trucking industry, tractor-trailers and other vehicles can use the Pyramid Wall System to offset fuel costs in part or in total. Tractor-trailers would benefit from several features of the Pyramid Wall System including, but not limited to the following:
• Container sides may be retrofitted to house Pyramid Wall sections or completely constructed out of Pyramid Wall sections. They may include single sided wall panels containing solar cells or any of the combinations of solar panel-capacitors.
• a flat cover 6000 and spherically concave cover 6010 are noted as well as a triangular shaped cavity seal 6005 for a flat cover and a triangular shaped cavity seal 6015 for a spherically concave cover.
• these cavity seals will be simply an end feature of a cover configuration, e.g., seal 6005 is part of cover 6000, seal 6015 is part of cover 6010, etc.
• Figure 216 shows a section view of the tractor-trailer showing a sample of the solar panel/supercapacitor wall.
• a cropped view normal to the section cut shows capacitors and flower panel wall cells.
• Transparent covers are removed to show a more detailed section view of the capacitor/flower assembly.
• An end view looking from back to front shows alternating small flukes 6760 and large flukes 6770.
• the solar panel configuration may be a stacked flower assembly 5700 as shown in the end view. Diagonally below that and to the right is a honeycomb latticed pyramid 6420 as part of a supercapacitor. This shows a cross section of a flower panel/supercapacitor array. To the right is a detailed view of the trailer section. Select covers are removed to reveal features of the array (petals and post in the flower 5700 and honeycomb features in the lattice 6420).
• Figure 217 shows a view from the front of a sectioned tractor-trailer.
• An exploded view of some transparent wall covers reveals asymmetrical Pyramid Wall cells, where the top sides are shorter than the bottom.
• the cab 6720 is shown for reference.
• a detail of an exploded area of a side panel is shown with several flat covers 6000 removed. Directly behind that is a sample of asymmetrical panels.
• pyramid configuration 4585 with uneven sides (shortened at the top) are used to best capture incident light from the bottom rows on a trailer.
• Panel sides and covers will be customizable.
• Figure 218 shows an angled view of a tractor-trailer with Pyramid Wall System 6700. Customizable aerodynamic features are shown in context of the whole vehicle.
• Sound walls are designed for the purpose of reflecting, diffusing or absorbing sound waves. For over fifty years they have been extensively used in the US as highway noise barriers. Residential and commercial developments have seen an increase of these barriers as well. They have been used for sound damping in concert halls and in studios where they can mute specific frequencies. They create the anechoic chambers in laboratories, which fully absorb and isolate all sound waves. Effectiveness, cost and esthetics are design factors, with most of the tradeoff between cost and effectiveness.
• Reflecting walls may be sufficient in rural areas, but generally transfer noise to areas in front of it. Competing reflective walls on opposite sides may actually increase noise in an area.
• Diffusing walls are the next most effective, but may have a more elaborate shape and higher cost.“S” shaped walls and walls with irregular geometric features fall into this category; they break up sound in front of it, not merely reflecting it to the other side.
• Absorbing walls are generally the most effective and most expensive. These include walls with acoustic foam, closed cell foam, pellets, earth and small rocks. Many sound walls have some combination of all three kinds of barrier.
• the Pyramid Wall System is a natural candidate for two of these sound wall categories: diffusion and absorption. Its unique shape diffuses sound by reflecting it within its array of inverted pyramid faces.
• a lattice may be printed in the inside face of one of the standalone wall sections, with the sections joined later, to provide increased reinforcement.
• Plugs and sockets may have drainage ports for moisture and heat.
• Pyramid spaces may have solar panels on one side, capacitor/battery combinations on the opposite or hybrid capacitor/solar panels on one side.
• Electroluminescent paint, electroluminescent tape and light-emitting diodes (LED)s on the outsides face of the innermost solar panels or the inside faces of the pyramid cells for nighttime use. LEDs may be individual components in an array, in a ribbon or in a sheet. Capacitor/battery combinations can make these lighted features self-sufficient.
• FIG. 5200 shows a completed sound wall section 6800.
• Figure 221 shows a completed sound wall section 6800 with a breakaway view exposing (in one non-limiting embodiment) closed cell foam 5210. In other configurations this insert may be pellets of plastic, recyclables including plastic, paper/pulp or concrete.
• Figure 222 shows a series of sound wall 6900. These segments may be of indefinite length, curved or angled, depending on design criteria.
• the involute surfaces of the Pyramid Wall Structure show a 119.6% increase in surface area over the base or footprint of the pyramid.
• Another non limiting embodiment of the Pyramid Wall Structure may only use panels for the base of the pyramid with the sides removed.
• a wind skirt may be added around the perimeter of these base sections to help keep panels pressed to the roof during drafts. Air vents may be added for moisture and heat ventilation.
• Figure 225 shows detail of the slotted base section 7210 and base 7210 to be connected.
• Figure 226 shows a triangular sidewall 7100 assembled and ready to connect to the slotted base section 7210 and onto the base 7220.
• Figure 227 shows two reference views of a triangular sidewall 7100 assembled into a slotted base section 7210 and the base 7220 waiting to be assembled.
• Figure 228 shows an assembly of four bases 7220, one triangular sidewall 7100 into one of the four slotted base sections 7210 and two frame member’s 7230 ready to assemble. In one non-limited embodiment these frame members may secure panels on the inside of the pyramid structure, so as to allow complete exposure of the panel edges and sides to the Sun.
• Figure 229 shows a completed Pyramid Wall Structure 7000 with its cap 7240 exploded over it.
• back to back wall panels may be used to house capacitors/batteries inside the pyramid’s structure. They may be in arrays in a solar farm and the shape of the individual cells may vary based on the optimum performance of solar collection.
• Figure 234 shows a Flat Pyramid Wall Building 7500.
• wind skirts are positioned to be secured.
• the panels, sides, base, slotted base frame and cap are replaced by a Pyramid Wall 4990 secured by Wall Sockets (5300) and an Aligning/Mounting Template/Fixture (5400).
• the perimeter of these panels is secured by a Wind Skirt 7510. This helps reduce strain on fasteners and bonding agents by taking advantage of downward drafts over buildings.
• LEDs may be used with inverters in this system; either on the backs of panels or on the inside faces of the pyramids. LEDs may be individual components in an array, in a ribbon or in a sheet. Transparent covers for weather and or air dispersion may be used.
• the solar panels may be assembled flat and hinged, creating a cross shaped pattern bonded or snap fit to the inside faces of pyramids.
• Solar panels may be flexible, formed as a cross shaped flat pattern and “4D” folded into a pyramid shape to be bonded or fit to the inside faces of pyramids.
• Solar panels may be single sided or bifacial and made with conventional manufacturing methods or 3D printed. They may be transparent in the visible spectrum and made of inorganic materials such as perovskite or organic salts. They may use graphene or equivalent superconductive material to create transparent nanowires or to coat conventional electrical contacts. Panel contacts may be arranged in a dense geometric pattern such as (but not limited to) a honeycomb shape, to increase contact surface area and efficiency. The panels and its contacts may be made with conventional manufacturing methods, 3D printed with conductive material or a combination of the two.
• Panels may have a transparent outer surface that functions as any type of conventional simple lens, lenticular lens or Fresnel lens. These lenses may be of a variety of shapes and have a variety of purposes including focusing, defocusing and redirecting light. Panels transparent or semi-transparent to visible light may have their outside faces coated with electroluminescent paint, electroluminescent tape or light-emitting diodes (LED)s. LEDs may be individual components in an array, in a ribbon or in a sheet. This will be for nightime use if transparent cells are used. These lighted faces will be self-sustaining, drawing power through an inverter connected to electrical storage such as supercapacitors and/or bateries in the Pyramid Wall modules. Electroluminescence may be powered by the capacitor or solar panel.
• LED light-emitting diodes
• Wall sections may be printed flat, with a living hinge to move into shape, either manually or with an outside stimulus, to be stacked for storage and transportation.
• Substitute materials for wrapping include: fiberglass and Kevlar.
• Substitute material for FFF/FDM 3D printing includes fiberglass and Kevlar (strands or chopped), thermoplastics (by themselves), concrete, cement, wood pulp, composite wood with binder, and recyclables. These materials can be fed as pellets, filaments or combinations thereof and extruded through the 3D printer nozzle.
• Substitute materials for various mold process include: wood pulp/composite wood, recyclable material (including plastic) and composite embedded thermoplastics, cement or concrete.
• Walls may be made out of sheet metal.
• Plugs and sockets can have aligned drainage ports for moisture and heat.
• a further embodiment provides a method to connect single sided Pyramid Wall sections to walls.
• a single sided Pyramid Wall section has their center posts form an electrical hub which connects the solar panel leads. This hub then connects into a cavity in a Wall Socket which has been mounted onto a wall or support surface.
• a fastener protrudes from the hub which is secured into an embedded, threaded insert in the Wall Socket cavity.
• the cavity has electrical contacts which then draw power from the hub and transfer it to a wiring harness or electrical conduits in an Aligning/Mounting Template/Fixture. Cutout sections in the Aligning/Mounting Template/Fixture have the same profile as a Wall Socket. Notches in the cutout sections provide relief for contact nipples in the Wall Sockets.
• the Aligning/Mounting Template/Fixture may be with or without electrical conduits or embedded wiring. It may be completely supported by sockets after they are fastened or bonded into a wall.
• the Aligning/Mounting Template/Fixture may be fastened or bonded independently to provide additional support for the Pyramid Wall Section.
• the Wall Sockets and Aligning/Mounting Template/Fixture may be machined, routed, laser cut, water cut or molded through various methods including injection molding. They may be formed through additive manufacturing, also known as 3D printing. They may be made in part or in full with specific 3D printing methods such as Fused Filament Fabrication (FFF), Fused Deposition Modeling (FDM), Stereolithography (SLA), Selective Laser Sintering (SLS) and Direct Metal Laser Sintering (DMLS).
• FFF Fused Filament Fabrication
• FDM Fused Deposition Modeling
• SLA Stereolithography
• SLS Selective Laser Sintering
• DMLS Direct Metal Laser Sintering
• Electrical contacts in the Wall Sockets and conduits in the Aligning/Mounting Template/Fixture may be a path for insulated wiring, over-molded wires or 3D printed with conductive material.
• the conduits may be coated with superconductive material such as Graphene or equivalent and/or filled with superconductive gel or any combination thereof.
• the Wall Sockets and Aligning/Mounting Template as a permanent fixture may have mounting holes to allow fastening to a mounting surface. They may be secured with bonding compound or a combination thereof.
• the Pyramid Wall System can take advantage of space within the pyramid space to position layers of semitransparent or transparent cells/panels to absorb specified wavelengths of visible and/or non-visible light.
• the first layer of solar panels may be single sided or bifacial and fastened to the inside faces of the pyramid housing. They may use graphene or equivalent superconductive material to create transparent nanowires or to coat conventional electrical contacts. Panel contacts may be arranged in a dense geometric pattern such as (but not limited to) a honeycomb shape, to increase contact surface area and efficiency.
• Panel layers may be coated with anti-reflective and/or polarizing compounds.
• ⁇ may be made with conventional manufacturing methods or through additive manufacturing, also known as 3D printing. They may be made in part or in full with specific 3D printing methods such as Fused Filament Fabrication (FFF), Fused Deposition Modeling (FDM), Stereolithography (SLA), Selective Laser Sintering (SLS) and Direct Metal Laser Sintering (DMLS).
• FFF Fused Filament Fabrication
• FDM Fused Deposition Modeling
• SLA Stereolithography
• SLS Selective Laser Sintering
• DMLS Direct Metal Laser Sintering
• a process which cures SLA resin with oxygen and UV light increases print speed up 25X to 100X. This ultrafast additive method is geared toward full production.
• the conductive paths that make up the mounting post wiring layers may contain embedded/over-molded wires. They may house molded, machined or 3D printed channels or conduits with inserted leads to create the wiring layers. The layers may have 3D printed conductive leads.
• the channels or conduits in the mounting posts may be sprayed or electroplated with conductive material or superconductive material such as graphene or equivalent. They may be coated with conductive or superconductive gel.
• transparent superconductive capacitors could be used between transparent cell layers for storage.
• the Flower Post’s hub is below the post body with a mounting fastener in place in the body’s countersunk hole.
• Panel recesses along the outside of the post’s body position the different levels of panels. Snap fit sockets allow snap fits on the access cap to secure it in place and protect the fastener. Access cap recesses allow tool access for quick release.
• the first level of wiring connects to the Cross Panel hinges. Negative and positive leads connect through the mounting hub. Multiple levels of wiring connect multiple levels of stacked panels.
• a completed Flower assembly may be folded into a pyramid shape, its outside surfaces coated with electroluminescent paint, electroluminescent tape or light-emitting diodes (LED)s.
• LEDs may be individual components in an array, in a ribbon or in a sheet. Panels may be transparent or semitransparent to different wavelengths depending on the requirements of the electroluminescent coating or LEDs.
• each panel may form a single, flat layer around the mounting post, where their exposed faces are parallel to the footprint of the pyramid.
• Each layer may be curved and concentrically nested around the mounting post.
• Each layer may be equally spaced or spaced differently along the mounting post.
• Each layer may be angled independently from each other or in any combination thereof.
• a first layer horizontal panel has an exposed face that is oriented parallel to the pyramid’s base or footprint. The edges of a clearance hole in the horizontal panel will be positioned just above the panel recesses in the flower post. Connecting tabs fit into the recesses to be bonded or fastened to the first layer horizontal panel. Subsequent panels may be assembled first, working toward the top. The first to be assembled on top of the cross panels may be the bottom panel with connecting tabs. Consecutive layers are assembled until the top layer panel and its connecting tabs. The assembly is then folded into a pyramid shape, its outside surfaces coated with electroluminescent paint, electroluminescent tape or LEDs.
• transparent covers may be used for various purposes within the Pyramid Wall System. They may be for protection from weather, to provide an aerodynamic surface or to aid in the collection or dispersion of light.
• the geometry of the covers may be flat, indented or protruding and be of varying shapes. They may cover individual cells, small panel sections or large arrays. They may be uniform or mixed depending on the application.
• Covers forming a protective barrier for solar panels may also provide protection for structures in windy areas. They may reduce drag when used to shield solar panels on moving vehicles. Data from wind tunnel tests and computer analysis such as computational fluid dynamics (CFD) will determine the specific geometry of a cover segment, as well as the arrangement of these segments over a large array.
• CFD computational fluid dynamics
• Covers may be coated with anti-reflective and/or or polarizing compounds.
• Covers may also be made through additive manufacturing, also known as 3D printing. They may be made in part or in full with specific 3D printing methods such as Fused Filament Fabrication (FFF), Fused Deposition Modeling (FDM), Stereolithography (SLA), Selective Laser Sintering (SLS) and Direct Metal Laser Sintering (DMLS).
• FFF Fused Filament Fabrication
• FDM Fused Deposition Modeling
• SLA Stereolithography
• SLS Selective Laser Sintering
• DMLS Direct Metal Laser Sintering
• a process which cures SLA resin with oxygen and UV light increases print speed up 25X to 100X. This ultrafast additive method is geared toward full production.
• Supercapacitors are designed for quick charging, while batteries are designed to provide long-term energy.
• Supercapacitors also called“ultracapacitors” are lightweight and have a high power density, meaning they can charge and discharge over a range of a fraction of a second to minutes. They maintain high efficiency over many years, millions of cycles and a wide range of temperatures, but are expensive and have limited storage.
• batteries have high energy density, meaning they can charge and discharge over the course several minutes to several hours. They are less expensive and have more storage than supercapacitors.
• their cycle life is much shorter.
• their operating temperature is limited and they degrade quickly under heavy loads such as intermittent solar power. By shifting load spikes to supercapacitors, the life of the battery can be extended. And as supercapacitor storage increases, it will complement batteries in applications such as electric vehicles, speeding up charge times significantly.
• Capacitor storage is directly related to the surface area of their electrodes, so a dense stacking of honeycomb layers was introduced as a method of increasing energy storage.
• the density of the layers within the supercapacitor and the number of layers may vary. These layers are coated with graphene, or equivalent nano-particles, creating additional surface area, which leads to higher storage capacity.
• the pattern of the electrodes may be an array of any geometry, not necessarily honeycomb. And the pattern on each layer may combine with the pattern on subsequent layers to make a specific 3D geometry to get optimum surface area.
• the layers are not restricted to being parallel to the base/footprint of the pyramid. Nor are they restricted to being parallel to each other or flat. They may be curved.
• a superconductive gel electrolyte is introduced between the layers which increases energy density, extending discharge time to match that of batteries.
• Additive Manufacturing also known as 3D printing
• the intricate geometries for these supercapacitors was not workable or they were prohibitively expensive. As the speed of this process increases, parts can move directly from prototype to manufacturing, driving costs down further.
• FFF Fused Filament Fabrication
• FDM Fused Deposition Modeling
• SLA Stereolithography
• SLS Selective Laser Sintering
• DMLS Direct Metal Laser Sintering
• a process which cures SLA resin with oxygen and UV light increases print speed up 25X to 100X. This ultrafast additive method is geared toward full production.
• the components of a supercapacitor cell include: cell cover, honeycomb lattice pyramid, supercapacitor casing and supercapacitor connection rack.
• Electrical contacts include the following: a positive serial post, positive electrical leads, a negative serial post and negative electrical leads.
• the posts provide a serial connection for each of the honeycomb layers, according to their charge.
• the positive leads and the negative leads will connect into posts on the supercapacitor casing which will snap fit into the supercapacitor connection rack.
• the rack has intemal wiring to draw current into two of its own leads that snap fit into sockets on the pyramid wall body. These leads then connect to the conductive elements in the bird-bone frame on the pyramid wall section.
• An alternate, hybrid configuration which combines supercapacitor layers and solar panel layers in a single pyramid cell may be used where there are space, weight and/or cost restrictions.
• the bottom section of the pyramid space would function as a capacitor, while the top would be for solar panels.
• This configuration allows for solar collection and storage on a single sided pyramid wall. This can be for applications where vertical space or depth or weight is limited.
• the Pyramid Wall System may provide power for refrigerated units, while the closed cell interior of the wall sandwich sections can provide thermal insulation.
• Electroluminescent paint, electroluminescent tape or light-emitting diodes (LED)s can provide night time illumination and/or signage through the panels and/or flukes. LEDs may be individual components in an array, in a ribbon or in a sheet. They can also use this illumination feature to augment signaling. Their low power consumption allows them to draw off of the capacitor-battery portion of the Pyramid Wall System without an external source.
• a luminescent layer can be a coat the back side of the last layer of panels or the inside faces of the pyramids. In one non-limiting embodiment, the top faces of the pyramids on the sides of a trailer may be coated for downward illumination.
• Container sides may be retrofitted to house Pyramid Wall sections or completely constructed out of Pyramid Wall sections. They may include single sided wall panels containing solar cells or any combinations of solar panel-capacitors.
• Pyramid Wall sections may have transparent covers for weather protection and a variety of dimple shapes. These covers can form side panels with shapes independently positioned and configured for maximum drag reduction. Some covers may have simple lens characteristics; either conventional, Fresnel or lenticular based on the position of the Pyramid Cell. In addition, pyramid cavities may have uneven sides in order to achieve the maximum potential solar collection, based on their position within the wall.
• the covers may be individually formed or made in a complete sidewall sheet. It would be followed by a post process to allow individual sections to be replaced in case of damage or if reconfigured.
• the covers may have drag reducing“Flukes” on the leading and trailing edges. These flukes may be individually formed or made in a complete sidewall sheet with the ability to be replaced. Drag reduction covers may be used on existing trailers without other features of the Pyramid Wall sections.
• dimpled covers are configurable and may be used without solar panels or electrical storage such as batteries or capacitors.
• the dimpled covers may also be used on conventional trailer sides without Pyramid Wall sections.
• a standalone trailer frame three wall sections the length of a trailer and two wall sections to fit the ends of a trailer are assembled.
• Wall sections can be made in various sizes and bonded together to make a complete trailer side or they can be made as a single panel, with or without connecting features or electrical features.
• Two side transparent, dimpled covers; one top transparent, dimpled covers and two end, transparent dimpled covers are added.
• a pyramid configuration with uneven sides can be used to capture incident light from the bottom rows on a trailer.
• Panel sides and covers can also be customizable.
• any of the operations described that form part of the presently disclosed embodiments may be useful machine operations.
• Various embodiments also relate to a device or an apparatus for performing these operations.
• the apparatus can be specially constructed for the required purpose, or the apparatus can be a general-purpose computer selectively activated or configured by a computer program stored in the computer.
• various general- purpose machines employing one or more processors coupled to one or more computer readable medium can be used with computer programs written in accordance with the teachings herein, or it may be more convenient to construct a more specialized apparatus to perform the required operations.

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