WO2024105665A1

WO2024105665A1 - Composite article that integrally incorporates a solar cell produced by a multi-cavity multi-layer mold, and systems and methods for mass production of such composite articles

Info

Publication number: WO2024105665A1
Application number: PCT/IL2023/051176
Authority: WO
Inventors: Ramon Joseph ALBALAK
Original assignee: Solarpaint Ltd.
Priority date: 2022-11-15
Filing date: 2023-11-14
Publication date: 2024-05-23

Abstract

Production systems and methods are configured for mass production of composite articles. Each composite article has an operable photovoltaic cell that is integrally incorporated in a molded component. A production system includes: a plurality of mold plates, that are stacked on top of each other or that are arranged next to each other; each pair of neighboring mold plates defines a respective mold cavity; the plurality of mold plates defines a plurality of discrete mold cavities that together are a multi-cavity multi-layer mold structure. Operable photovoltaic cells are provided for placement as inserts within the discrete mold cavities. Reinforcement materials are placed above or beneath each operable photovoltaic device within a respective mold cavity. An injector unit injects a hot or heated or molten or liquid resin or other molding material, at a particular pressure, simultaneously into the discrete mold cavities of the multi-cavity multi-layer mold structure, through a plurality of injection ports.

Description

Composite Article that Integrally Incorporates a Solar Cell Produced by a Multi-Cavity Multi-Layer Mold, and Systems and Methods for Mass Production of Such Composite Articles

Cross-Reference to Related Applications

[0001] This patent application claims priority and benefit from US 63/425,328, filed on November 15, 2022, which is hereby incorporated by reference in its entirety.

[0002] At least for the purposes of the United States, the following priority rights and/or benefit rights are also claimed for the present application, and the following status as Continuation and/or as Continuation-in-Part (CIP) is also claimed for the present application: [0003] This patent application is also a Continuation-in-Part (CIP) of, and claims benefit and/or priority from: patent application US 18/129,865, filed on April 2, 2023, which is hereby incorporated by reference in its entirety.

[0004] The above-mentioned US 18/129,865 is a Continuation of PCT international patent application number PCT/IL2021/051202, having an international filing date of October 7, 2021, which is hereby incorporated by reference in its entirety.

[0005] The above-mentioned PCT/IL2021/051202 claims priority and benefit: (i) from US 63/088,535, filed on October 7, 2020, which is hereby incorporated by reference in its entirety; and (ii) from US 17/353,867, filed on June 22, 2021, which is hereby incorporated by reference in its entirety.

[0006] The above-mentioned US 18/129,865 is also a Continuation-in-Part (CIP) of US 17/353,867, filed on June 22, 2021, which is hereby incorporated by reference in its entirety.

[0007] The above-mentioned US 17/353,867 is a Continuation-in-Part (CIP) of US 16/362,665, filed on March 24, 2019, now patent number US 11,081,606 (issued on August 3, 2021), which is hereby incorporated by reference in its entirety; which claims priority and benefit from US 62/785,282, filed on December 27, 2018, which is hereby incorporated by reference in its entirety.

[0008] The above-mentioned US 17/353,867 is also a Continuation-in-Part (CIP) of PCT international application number PCT/IL2019/051416, having an international filing date of December 26, 2019, which is hereby incorporated by reference in its entirety.

[0009] The above-mentioned PCT/IL2019/051416 claims priority and benefit: (i) from US 16/362,665, filed on March 24, 2019, now patent number US 11,081,606 (issued on August 3, 2021), which is hereby incorporated by reference in its entirety, and (ii) from US 62/785,282, filed on December 27, 2018, which is hereby incorporated by reference in its entirety.

[0010] The above-mentioned US 18/129,865 is also a Continuation-in-Part (CIP) of US 17/802,335, filed on August 25, 2022, which is hereby incorporated by reference in its entirety; which is a National Stage of PCT international application number PCT/IL2021/050217, having an international filing date of February 25, 2021, which is hereby incorporated by reference in its entirety; which claims priority and benefit from US 62/982,536, filed on February 27, 2020, which is hereby incorporated by reference in its entirety.

[0011] This patent application is also a Continuation-in-Part (CIP) of, and claims benefit and/or priority from: patent application US 18/372,720, filed on September 26, 2023, which is hereby incorporated by reference in its entirety.

[0012] The above-mentioned US 18/372,720 is a Continuation of PCT international application number PCT/IL2022/050339, having an international filing date of March 29, 2022, which is hereby incorporated by reference in its entirety.

[0013] The above-mentioned PCT/IL2022/050339 claims priority and benefit from US 63/167,660, filed on March 30, 2021, which is hereby incorporated by reference in its entirety. [0014] The above-mentioned PCT/IL2022/050339 also claims priority and benefit from PCT international application number PCT/IL2021/051202, having an international filing date of October 8, 2021, which is hereby incorporated by reference in its entirety.

[0015] The above-mentioned PCT/IL2022/050339 also claims priority and benefit from PCT international application number PCT/IL2021/051269, having an international filing date of October 27, 2021, which is hereby incorporated by reference in its entirety.

[0016] The above-mentioned PCT/IL2022/050339 also claims priority and benefit from PCT international application number PCT/IL2022/050030, having an international filing date of January 10, 2022, which is hereby incorporated by reference in its entirety.

[0017] The above-mentioned PCT/IL2022/050339 also claims priority and benefit from patent application US 17/353,867, filed on June 22, 2021, which is hereby incorporated by reference in its entirety.

[0018] The above-mentioned US 18/372,720 is also a Continuation-in-Part (CIP) of US 18/136,359, filed on April 19, 2023, which is hereby incorporated by reference in its entirety. The above-mentioned US 18/136,359 is a Continuation of PCT international application number PCT/IL2021/051269, having an international filing date of October 27, 2021, which is hereby incorporated by reference in its entirety. The above-mentioned PCT/IL2021/051269 claims priority and benefit: (i) from US 63/106,666, filed on October 28, 2020, which is hereby incorporated by reference in its entirety; and also, (ii) from US 17/353,867, filed on June 22, 2021, which is hereby incorporated by reference in its entirety.

[0019] The above-mentioned US 18/372,720 is also a Continuation-in-Part (CIP) of US 18/217,620, filed on July 3, 2023, which is hereby incorporated by reference in its entirety; which is a Continuation of the above-mentioned PCT international application number PCT/IL2022/050030, having an international filing date of January 10, 2022, which is hereby incorporated by reference in its entirety.

Field

[0020] Some embodiments relate to the field of solar panels and photovoltaic (PV) devices.

Background

[0021] The photovoltaic (PV) effect is the creation of voltage and electric current in a material upon exposure to light. It is a physical and chemical phenomenon.

[0022] The PV effect has been used in order to generate electricity from sunlight. For example, PV solar panels absorb sunlight or light energy or photons, and generate electricity through the PV effect.

Summary

[0023] Some embodiments provide a composite article that integrally incorporates an operable solar cell or photovoltaic device. The composite article is produced by a multi-cavity / multi-layer mold structure, via a Resin Transfer Molding (RTM) process or other suitable or similar process. Some embodiments provide systems and methods for mass production a plurality of such composite articles.

[0024] Some embodiments provide a production system for mass production of a plurality of discrete composite articles; wherein each composite article comprises an operable photovoltaic cell that is integrally incorporated in a molded component. For example, the production system comprises: (a) a plurality of mold plates, that are stacked on top of each other or that are arranged next to each other; wherein each pair of neighboring mold plates, defines a respective mold cavity; wherein the plurality of mold plates defines a plurality of discrete mold cavities that together are a multi-cavity multi-layer mold structure; (b) a plurality of operable photovoltaic cells, wherein each operable photovoltaic cell is configured for placement as an insert within one of said plurality of discrete mold cavities; (c) one or more reinforcement materials, configured for placement above and/or beneath each operable photovoltaic device within a respective mold cavity; (d) an alignment mechanism, to align the plurality of mold plates and to mechanically maintain the mold plates in place; (e) a plurality of injection ports, wherein each injection port is configured to provide a molding material into one of the discrete mold cavities; (f) an injector unit, configured to inject said molding material at a heated or molten state, at a particular pressure, simultaneously into said plurality of discrete mold cavities of said multi-cavity multi-layer mold structure, through said plurality of injection ports.

[0025] Some embodiments may provide other and/or additional benefits and/or advantages.

Brief Description of the Drawings

[0026] Fig. 1 is a schematic illustration of a system capable of performing an RTM process; which may be used, or may be configured or modified to operate, in accordance with some demonstrative embodiments.

[0027] Fig. 2A is a schematic illustration of a side-view of an innovative multi-cavity / multi-layer mold, which may be used in conjunction with an RTM system or process or with other types of injection system or process, particularly configured to enable mass production of a plurality of discrete injected / composite articles that integrally incorporate a solar cell or a photovoltaic device, in accordance with some demonstrative embodiments.

[0028] Fig. 2B is a schematic illustration of a side-view of the multi-cavity / multi-layer mold, together with an enlarged or zoomed-in region thereof, in accordance with some demonstrative embodiments.

[0029] Fig. 2C is a schematic illustration of a top-view of a mold plate (from the above- mentioned plurality of mold plates of the multi-cavity / multi-layer mold), in accordance with some demonstrative embodiments.

[0030] Fig. 2D is a schematic illustration of a side-view of another innovative multi-cavity / multi-layer mold structure, which may be used in conjunction with an RTM system or process or with other types of injection system or process, particularly configured to enable mass production of a plurality of discrete injected / composite articles that integrally incorporate a solar cell or a photovoltaic device, in accordance with some demonstrative embodiments.

[0031] Fig. 3 A is a schematic illustration of a multi-layer / multi-cavity mold structure, in accordance with some demonstrative embodiments.

[0032] Fig. 3B is a schematic illustration of another multi-layer / multi-cavity mold structure, in accordance with some demonstrative embodiments. Detailed Description of Some Demonstrative Embodiments

[0033] Some embodiments provide a composite article that integrally incorporates a solar cell produced by a multi-cavity mold or Resin Transfer Molding (RTM) process, or other suitable or similar process (e.g., injection molding, blow molding, rotational molding); as well as systems and methods for mass production of such composite articles.

[0034] In some embodiments, one or more solar cells are integrally incorporated into one or more composite materials to form an integrated composite article, using RTM and/or similar processes in which resin is injected into a multi-cavity mold and/or a multi-layer mold.

[0035] Some embodiments further provide system and method for producing such composite article; as well as systems and methods for producing two or more such composite articles in parallel or simultaneously or concurrently, or via a single injection operation or via a single RTM process that yields two or more such discrete composite articles.

[0036] A solar cell or solar panel, or a photovoltaic (PV) cell or PV device, is an electrical device that converts the energy of light or photons directly into electricity (e.g., electric current, electric voltage) via the photovoltaic effect, which is a physical and chemical phenomenon. Solar cells are typically configured as a large-area p-n junction made from silicon. Other possible solar cell types are thin film solar cells, Cadmium Telluride (CdTe) solar cells, Copper Indium Gallium Diselenide (CIGS) solar cells, an Organic Solar Cell (OSC), a Dye-Sensitized Solar Cell (DSSC), a Perovskite Solar Cell (PSC), a Quantum Dot Solar Cells (QDSC), or the like.

[0037] In a typical solar cell, the following process is performed: (a) Photons of sunlight or other light hit the solar cell, and are absorbed by a semiconducting material (e.g., silicon); (b) Electrons are excited by the incoming photons from their current molecular / atomic orbital in the semiconducting material; (c) Once excited, an electron can either dissipate the energy as heat and return to its orbital, or travel through the solar cell until it reaches an electrode; (d) electric current flows through the semiconductor material to cancel the electric potential, and this electricity is captured or collected. The chemical bonds of the solar cell material are important for this process to work; typically, silicon is used in two regions: a first region being doped with boron, and a second region being doped with phosphorus. These regions have different chemical electric charges and thus drive and direct the current of electrons towards a relevant electrode. An array of solar cells converts solar energy into a usable amount of Direct Current (DC) electricity. A plurality or group or batch of individual solar cell devices can be combined or aggregated to form a solar module or a solar panel. Optionally, an inverter is used to convert Direct Current (DC) from a panel into Alternating Current (AC). [0038] In order to produce a robust, durable, and useable product, a solar cell can be encapsulated in protective materials. The active side or the “sunny side” of the solar cell, which is intended to face the incoming light or sunlight, should be transparent or translucent (or, at least partially transparent or translucent) in order to allow light photons to reach the active photovoltaic material. Such encapsulation materials may include, for example, glass, polymeric sheets, and other encapsulant materials.

[0039] Some implementations may incorporate a solar cell in composite material(s) in a process that produces an integrated composite article; for example, using a pre-preg method that utilizes pre-impregnated fibers, or using an autoclave machine. Incorporation of solar cells in composite materials can also be performed using a Resin Transfer Molding (RTM) process via a single-cavity mold

[0040] Some embodiments may utilize an RTM process for composite articles or components. In such RTM process, a mechanically-clamped, rigid, normally two-part (malefemale) mold is utilizes. Some demonstrative advantages of using a “closed mold” RTM process are: (a) volatile emissions are reduced; (b) the process can be fast, clean, and repeatable; (c) the laminate thickness can be closely controlled; (d) the process is less reliant on the manual skills of the operator; (e) the “B” surface of the molding can be accurately defined; (f) the process can be automated.

[0041] Reference is made to Fig. 1, which is a schematic illustration of a system 100 capable of performing an RTM process; which may be used, or may be configured or modified to operate, in accordance with some demonstrative embodiments. System 100 demonstrates a single-cavity mold; however, the system may be modified or configured to become a dualcavity mold system, or a dual-layer mold system, or a multiple-cavity mold system, or a multiple-layer mold system.

[0042] In accordance with some implementations of the RTM system, dry reinforcement (e.g., glass, carbon, aramid, aramid fibers or aromatic polyamide fibers or other heat-resistant and strong synthetic fibers) is placed between a two-part mold; and the mold is then clamped shut using mechanical force (e.g., hydraulic press, nuts and bolts, heavy duty toggle clamps, or other clamping mechanism or vise). The mold flanges compress a peripheral seal which prevents resin leaks from the mold, and may also be vacuum-tight. Thermosetting resin is injected, such as centrally, directly into the fiber-pack; and the mold is filled by positive hydraulic pressure from the injection machine. The mold is vented at the furthest points from the injection point, allowing air to escape. Vacuum can also be drawn from the vents to improve laminate quality. Some RTM implementations require that the mold / clamping structure would be sufficiently stiff or rigid, to withstand the pressure of the injected resin without causing opening or distorting of the mold or the clamping mechanism.

[0043] Some embodiments may be configured to enable mass production or large-scale production or efficient production of composite parts or composite articles in which solar cells or PV cells are integrally incorporated into composite material using an RTM process (or a similar process), by utilizing a multi-cavity mold or a multi-layer mold.

[0044] Reference is made to Fig. 2A, which is a schematic illustration of a side-view of an innovative multi-cavity / multi-layer mold 200, which may be used in conjunction with an RTM system or process or with other types of injection system or process, particularly configured to enable mass production of a plurality of discrete injected / composite articles that integrally incorporate a solar cell or a PV device, in accordance with some demonstrative embodiments. Other components are used in conjunction with the mold 200 (e.g., injection ports, vent ports, reinforcement; and/or components shown in system 100), and they are not shown in Fig. 2A in order to prevent over-crowding of the drawing.

[0045] For example, a plurality of discrete Mold Cavities 213 are shown, separated by and/or enclosed by and/or defined by Mold Plates 214. Alignment Rods 211 are utilized as a framing / supporting component; and one or more Seals 212 or sealing members or sealing elements are further used.

[0046] For demonstrative purposes, and as a non-limiting example, the multi-cavity / multi-layer mold structure of Fig. 2A depicts the mold plates as being stacked generally horizontal, one mold plate over or beneath another mold plate, and/or being generally parallel to a floor or a ground, and/or as being generally perpendicular to the direction of gravity (indicated with an arrow). However, other embodiments may utilize other arrangements for the multi-cavity / multi-layer mold structure; for example, arranging or placing or stacking the mold plates side-by-side, and/or generally perpendicular to the floor or to the ground, and/or generally parallel to the direction of gravity. In still other embodiments, the mold plates may be arranged in a structure that is slanted or diagonal, and/or non-horizontal and/or non-vertical; for example, in order to achieve an efficient stacking in a particular production system, or to efficiently utilize a particular space that is available for production, or to enable improved connection or easier connection to the injection machine or to other components of the system. In still other embodiments, the multi-cavity / multi-layer mold structure may include a combination of mold plates that are, for example: generally horizontal, and/or general vertical, and/or slanted or diagonal, and/or non-horizontal, and/or non-vertical, and/or having a particular alignment or spatial direction in order to achieve a particular functional goal; while also ensuring that the functionality of the multi-cavity / multi-layer mold is maintained, such as, by ensuring that injection ports / inlets can be provided, by ensuring that the configuration enables passage of injection pipes or tubes or components, by ensuring that there is room for venting outlets or venting ports, or the like.

[0047] Reference is made to Fig. 2D, which is a schematic illustration of a side-view of an innovative multi-cavity / multi-layer mold 240, which may be used in conjunction with an RTM system or process or with other types of injection system or process, particularly configured to enable mass production of a plurality of discrete injected / composite articles that integrally incorporate a solar cell or a PV device, in accordance with some demonstrative embodiments. The multi-cavity / multi-layer mold 240 is rotated by 90 degrees relative to the mold structure 200 of Fig. 2A; such that the mold plates of the multi-cavity / multi-layer mold 240 are arranged side-by-side next to each other, each mold plate being generally vertical, or each mold plate being generally perpendicular to the floor or the ground, or each mold plate being generally parallel to the direction of gravity. As mentioned above, this is only a nonlimiting example of another multi-cavity / multi-layer mold structure having a particular spatial arrangement and orientation of the mold plates.

[0048] Reference is made to Fig. 2B, which is a schematic illustration of a side-view of the multi-cavity / multi-layer mold 200, together with an enlarged or zoomed-in region thereof, in accordance with some demonstrative embodiments. As shown, an operable solar cell or PV device, or a plurality or array or group of operable solar cells or operable PV devices, is intended for insertion into the mold cavity; and is further intended to be constrained on its first side (e.g., upper side) by Side 1 Layer(s) as shown, and/or is further intended to be constrained on its second side (e.g., lower side) by Side 2 Layer(s) as shown. Such layer(s) may include, for example, fibers, particles, granules, fabrics, polymers, or other materials; and they are incorporated into the final composite product through the molding process.

[0049] In some embodiments, the additional molding materials are placed only on Side 1 of the solar cell (e.g., only on its upper side or its “sunny side” or its active side), and not on Side 2 of the solar cell. In other embodiments, the additional molding materials are placed only on Side 2 of the solar cell (e.g., only on beneath its lower side or beneath its “dark side”), and not on Side 1 of the solar cell. In other embodiments, a first set of one or more additional molding material(s) is placed on top of Side 1 of the solar cell; and a second, different, set of one or more additional molding materials) is placed on top of Side 2 of the solar cell.

[0050] Additionally or alternatively, in some embodiments, the volume (or thickness) of the Side 1 materials is denoted DI; whereas, the volume (or thickness) of the Side 2 materials is denoted D2. In some embodiments, DI > D2, such that the thickness (or height) of the Side 1 materials is greater than the thickness (or height) of the Side 2 materials. In other embodiments, DI < D2, such that the thickness (or height) of the Side 2 materials is greater than the thickness (or height) of the Side 1 materials. In some embodiments, DI = D2, such that the thickness (or height) of the Side 1 materials is equal to the thickness (or height) of the Side 2 materials. In some embodiments, DI = 0, such that no Side 1 materials are used at all. In some embodiments, D2 = 0, such that no Side 2 materials are used at all.

[0051] In some embodiments, the materials included in the Side 1 layer(s) are transparent or translucent, or are at least partially transparent or translucent (e.g., enabling passage therethrough of at least 75 or 80 or 85 or 90 or 95 or 99 percent of incoming light). Additionally or alternatively, in some embodiments, the materials included in the Side 2 layer(s) are transparent or translucent, or are at least partially transparent or translucent (e.g., enabling passage therethrough of at least 75 or 80 or 85 or 90 or 95 or 99 percent of incoming light). [0052] Reference is made to Fig. 2C, which is a schematic illustration of a top-view of a mold plate 214 (from the plurality of mold plates of the multi-cavity / multi-layer mold 200), in accordance with some demonstrative embodiments. It demonstrates a single “layer” of the multiple-layer mold, which includes or utilizes alignment elements for registration between the different layers of cavities. In a demonstrative embodiment, all the mold plates 214 are stacked as layers on top of each other, and have the same size; and each mold plate 214 has a plurality of alignment holes 215 (shown in an exaggeratedly large size, for clarity), such as near or at the four corners of the generally-rectangular (or square-shaped) mold plate 214, to enable passage of a vertical alignment rods through a set of such corresponding alignment holes 215 of a plurality of such stacked mold plates 214. In other embodiments, other alignment mechanisms may be used; for example, all the mold plates may be pushed towards a particular direction until they touch a common frame or wall or panel or border (e.g., made of metal) that defines an edge or a corner, such that the stack of mold plates are all aligned relative to each other as each mold plate touches such common metal edge or common metal corner. In other embodiments, alignment may be achieved via elongated screws that traverse vertically through the alignment holes 215.

[0053] Reference is made to Fig. 3A, which is a schematic illustration of a multi-layer / multi-cavity mold 300, in accordance with some demonstrative embodiments. For demonstrative purposes, only two cavities or two layers are shown, to allow clear and large depiction of the components; however, some embodiments may utilize dozens or even hundreds of such cavities or layers, stacked on top of each other. [0054] For example, mold plates 321 and 322 and 323 are shown, defining two mold cavities 371 and 372. Each mold plate operates as a top mold part and/or as a lower mold part. For example, mold plate 321 is the upper mold part with regard to mold cavity 371; and mold plate 322 is the lower mold part with regard to mold cavity 372. Mold plate 323 is the lower mold part with regard to mold cavity 372; and mold plate 322 is the upper mold cavity with regard to mold cavity 372. Accordingly, mold plate 322 acts both (i) as the upper mold part for mold cavity 372, and (ii) as the lower mold part for mold cavity 371.

[0055] In some embodiments, optionally, each mold plate 321 / 322 / 323, or some of them, may have protrusions and/or craters and/or ribs and/or other three-dimensional non-planar features, and/or curved regions and/or concave regions and/or convex regions; to enable formation of a composite article having particular three-dimensional features that complement such respective features of the mold plate. For demonstrative purposes, the lower side of mold plate 321 is demonstrated as having a generally rectangular protruding element 362, and a generally trapezoid protruding element 361; and similar protruding elements are also located at the lower side of mold plate 322. As another example, curved or dome-shaped protruding elements 363 and 364 are located at the top side of mold plate 322 and also at the top side of mold plate 323. Other suitable types of three-dimensional features may be used, to obtain a particular three-dimensional structure for the composite article.

[0056] The mold plates 321-323 are aligned, and the mold cavities 371 and 372 are sealed, using alignment and sealing units 324 and 325. For demonstrative purposes, and since this is a side-view or cross-sectional view, only two such alignment and sealing units 324 and 325 are shown; however, four or eight or other number of such alignment and sealing units may be used, for example, at for corners and/or at four edges and/or at four sides of each mold plate, or otherwise surrounding each mold plate and/or each mold cavity and ensuring alignment and hermetic sealing.

[0057] Mold cavity 371 has an injection port or inlet 331; mold cavity 372 has an injection port or inlet 332; enabling injection / high-velocity / high-pressure / medium-pressure / low- pressure entry of molten materials or semi-molten materials.

[0058] Mold cavity 371 has a ventilation port or outlet 341; mold cavity 372 has a ventilation port or outlet 342; enabling exiting or removal of air and/or creation of vacuum (e.g., via an optional suction unit) upon entry of the injected molten material, that are provided or injected from an injector 333 which obtains them from a (typically heated) repository or container. [0059] Prior to the closing, sealing and clamping of the mold cavities, operable solar cells or operable PV devices are placed as inserts within the mold cavities. For example, a solar module 311 having a plurality of inter-connected solar cells, is placed as an insert inside mold cavity 371. Similarly, a solar module 312 having a plurality of inter-connected solar cells, is placed as an insert inside mold cavity 372. In some embodiments, solar module 311 / 312 is maintained at particular position or location or angle or slanting within the respective mold cavity, by using a mounting / holding unit or mechanism; for example, by bonding or gluing or taping the solar module to a particular side or inner panel or protrusion within the mold cavity, or by using a mounting rod or mounting pin, or by using magnetic force, or by other holding means or placement maintenance mechanism.

[0060] In some embodiments, solar module 371 / 372 includes, or is, a flexible and/or rollable and/or foldable and/or non-brittle solar cell(s); and particularly, a solar cell in which the semiconductor wafer has craters or trenches or non-transcending gaps that penetrate into 51 to 99 percent of the depth (or height) of the semiconductor wafer, and leave a thin layer of the semiconductor wafer intact and non-penetrated; and such that the non-transcending gaps or craters are filled, entirely or dominantly or at least partially, with a filler material (e.g., elastomer) that enhances the mechanical / thermal / chemical resilience of the solar cell; and such that this unique structure of non-transcending gaps or craters, with the optional filler material in them, dissipate mechanical shocks and mechanical forces that are applied to the solar cell, and provide to the solar cell increased resilience that enables it to withstand the high temperature and/or pressure during the molding process without being operably damaged (at all, or significantly).

[0061] Prior to the closing, sealing and clamping of the mold cavities, one or more reinforcement materials (381, 382) are inserted into each mold cavity, to surround the operable solar module or to cover the operable solar module or to cover exactly one side of the operable solar module or to cover two sides of the operable solar module, or to otherwise touch at least one edge or side of the operable solar module, or to otherwise be inside the mold cavity and in proximity to the operable solar module. Such reinforcement material(s) 381 / 382 may be or may include, for example, glass, fiber, fiber-glass, glass-fiber, carbon, carbon fibers, aramid, flax, natural fibers, granules or pellets or particles or powder of the above material(s), and/or other suitable reinforcement materials that can provide a protective cover and/or a protective surrounding to the solar module in the final composite article, or a combination or mixture of two or more such materials. In some embodiments, the reinforcement materials are transparent or translucent, in their raw state and/or in their post-molding state, or they are at least partially or dominantly transparent or translucent (e.g., enabling passage therethrough of at least 75 or 80 or 85 or 90 or 95 percent of incoming light).

[0062] After the placement of the solar module(s) and the reinforcement material(s) within the mold cavity, the mold cavities are closed, aligned, and sealed. Molten or heated or semimolten materials are injected by the injector 333 through the injection ports 331-332, and a molding process is performed. The multi-cavity / multi-layer mold structure is then cooled down, using an optional cooling unit or by allowing it to cool-down by itself and get back to room temperature over time. The mold cavities are opened, and the plurality of discrete composite articles are ejected or pulled out from the mold cavities; each composite article having an integral / integrated solar module, which remains operable even after the molding process. A single injection operation may thus be used to produce, in parallel or concurrently or simultaneously, a large number (dozens, or even hundreds) of composite articles.

[0063] In some embodiments, optionally, the mold plates may be gradually stacked one on top of the other, to enable gradual construction of the pre-molding structure. For example, the bottom mold plate 323 is placed; then, on top of it, reinforcement material 382 is added; then, on top of it, solar module 312 is placed; then, on top of it, reinforcement material 381 is added; then, on top of it, mold plate 322 is placed; then, on top of it, reinforcement material 382 is added; then, on top of it, solar module 311 is placed; then, on top of it, reinforcement material 381 is added; then, on top of it, mold plate 321 is placed; then, the multi-cavity / multi-layer mold structure is aligned, and then sealed; and then the injection is performed.

[0064] Reference is made to Fig. 3B, which is a schematic illustration of a multi-layer / multi-cavity mold 302, in accordance with some demonstrative embodiments. It is generally similar to mold structure 300 of Fig. 3 A, but is rotated by 90 degrees relative to mold structure 300 of Fig. 3A. For example, the mold plates of mold structure 302 of Fig. 3B are generally perpendicular to the floor or the ground, and/or are generally vertical, and/or are generally parallel to the direction of gravity (indicated by an arrow). The mold structure 302 may be placed directly on a production floor or on the ground, or on an elevated production surface; or may be mounted or placed on top of pedestals 391-393 or other support elements for a particular functional goal (e.g., to leave room or a gap for ventilation or venting outlets, or to leave room or a gap for injector inlets or injector ports). Other suitable arrangements of mold plates may be used.

[0065] Some embodiments may be configured to enable mass production of various types of composite articles that incorporate solar cells or PV devices; for example, a vehicular part or vehicular component (e.g., vehicular roof, vehicular door, vehicular trunk, vehicular side panel, vehicular hood), a marine vessel component or part, an aircraft or spacecraft component or part, a roof or roof-part or roof-portion or shingle, a wall or a construction panel, an advertising board or billboard, a traffic divider, a sidewalk element or tile, a floor tile, a standalone / off-grid PV device or solar panel, a composite article that can float on water or on sear water or in a body of water, or the like.

[0066] Additional / Optional Features:

[0067] In some embodiments, a solar cell or solar panel or PV device that is utilized may be an autonomously flexible and/or rollable and/or foldable solar cell, that does not break and does not brittle when flexed or curved or bent or folded or rolled, and that is resilient to mechanical forces, and that can autonomously absorb and/or dissipate and/or withstand mechanical forces and mechanical shocks; for example, by being singulated or segmented or grooved or trenched with non-transcending gaps or “blind gaps” or craters or grooves or trenches, that penetrate some - but not all - of the thickness (or the depth) of a silicon layer or a semiconductor body or a semiconductor wafer; and optionally by having filler material(s) in such grooves or trenches or non-transcending gaps or non-transcending craters, to further absorb and/or dissipate mechanical forces and shocks.

[0068] Optionally, some embodiments may be utilized in conjunction with PV devices and/or solar panels and/or components and/or methods that are described in patent number US 11,081,606, titled “Flexible and rollable photovoltaic cell having enhanced properties of mechanical impact absorption”, which is hereby incorporated by reference in its entirety; and/or in conjunction with components, structures, devices, methods, systems and/or techniques that are described in patent application number US 17/353,867, filed on June 22, 2021, published as US 2021/0313478 Al, which is hereby incorporated by reference in its entirety; and/or with solar panels or solar cells or PV devices that are singulated or segmented or trenched or grooved, or that are flexible and/or rollable and/or foldable, and/or that include “blind gaps” or non-transcending gaps or craters. Some embodiments may provide a flexible and rollable PV cell or solar cell; wherein a silicon body or semiconductor body or semiconductor substrate or semiconductor wafer has non-transcending craters or “blind gaps” that penetrate into between 75 percent and 99 percent of a total thickness of the semiconductor body (or wafer, or substrate), and that do not penetrate into an entirety of the total thickness of the semiconductor body (or wafer, or substrate); wherein said non-transcending craters or “blind gaps” increase flexibility/or and mechanical resilience and/or mechanical shock absorption of the PV cell. In some embodiments, some, or most, or all of the non-transcending craters or “blind gaps” contain a filler material having mechanical force absorption properties, which provides mechanical shock absorption properties and/or mechanical force dissipation properties to the PV cell.

[0069] In some embodiments, each of the solar cells is rollable and flexible by itself; and is a single PV device or is a single PV article, that is comprised of a single semiconductor substrate or a single semiconductor wafer or a single semiconductor body; which is monolithic, e.g., is currently, and has been, a single item or a single article or a single component that was formed as (and remained) a single component; such that each solar cell is not formed as a collection or two or more separate units or as a collection of two or more entirely-separated or entirely-discrete or entirely-gapped units that were arranged or placed together in proximity to each other yet onto a metal foil or onto a metal film or onto a flexible or elastic foil or film.

[0070] In some embodiments, each single solar cell that is flexible and rollable by itself, is not a collection and is not an arrangement and is not an assembly of multiple discrete solar cells of PV modules, that each one of them has its own discrete and fully separated semiconductor substrate and/or its own discrete and fully separated semiconductor wafer and/or its own discrete and fully separated semiconductor body, and that have been merely placed to assembled or arranged together (or mounted together, or connected together) onto or beneath a flexible foil or a flexible film; but rather, the each single solar cell has a single unified semiconductor substrate or semiconductor body or semiconductor wafer that is common to, and is shared by, all the sub-regions or areas or portions of that single solar cell which includes therein (in that unified single semiconductor substrate or wafer or body) those nontranscending craters or non-transcending gaps or “blind gaps” that penetrate only from one side (and not from both sides), which do not reach all the way through and do not reach all the way to the other side of the unified single semiconductor substrate or wafer or body.

[0071] In some embodiments, each solar cell may be, or may include, a mono-crystalline PV cell or solar panel or solar cell, a poly-crystalline PV cell or solar panel or solar cell, a flexible PV cell or solar cell that is an Interdigitated Back Contact (IBC) solar cell having said semiconductor wafer with said set of non-transcending gaps, and/or other suitable type of PV cell or solar cell.

[0072] Some portions of the discussion above and/or herein may relate to regions or segments or areas, of the semiconductor body or substrate or wafer (or PV cell, or PV device); yet those “segments” are still touching each other and/or inherently connected to each other and/or non-separated from each other, as those “segments” are still connected by at least a thin portion or a thin bottom-side surface of the semiconductor substrate (or wafer, or body), which still holds and includes at least 1 (or at least 2, or at least 3, or at least 5, or at least 10, or at least 15, or at least 20, or at least 25, or at least 33; but not more than 50, or not more than 40) percent of the entire depth or the entire thickness (or the maximum thickness or depth) of the semiconductor substrate or body or wafer; as those “segments” are still connected at their base through such thin layer, and those “segments” have between them (or among them) the nontranscending gaps or the “blind gaps” or the non-transcending craters that thus separate those “segments” but that do not fully divide or fully break or fully isolate any two such neighboring “segments” from each other. Upon its production, and prior to attaching the solar cells onto the floating medium layer, each such flexible and rollable solar cell is freestanding and carrier-less and non- supported.

[0073] In some embodiments, the non-transcending gaps or the “blind gaps” or craters or slits or grooves, are introduced and are formed only at a first side or at a first surface of the semiconductor substrate or body or wafer, and are not formed at both of the opposite surfaces (or sides) thereof.

[0074] In some embodiments, the non-transcending gaps or the “blind gaps” or craters or slits or trenches or grooves, are introduced and are formed only at a first side or at a first surface of the semiconductor substrate or body or wafer, that is intended to face the sunlight or the light, or that is the active side of the PV device or PV cell, or that is intended to be the active side of the PV device or PV cell, or that is intended to be the electricity-generating side or surface that would generated electricity based on incoming sunlight or light or based on the PV effect; and they are not formed at the other (e.g., opposite, non-active) side or surface (e.g., the side that is not intended to be facing the sunlight or the light, or the side that is not intended to be producing electricity based on the PV effect).

[0075] In other embodiments, the non-transcending gaps or the “blind gaps” or craters or slits or trenches or grooves, are not introduced and are not formed at the side or surface of the semiconductor substrate or body or wafer, that is intended to face the sunlight or the light, or that is the active side of the PV device or PV cell, or that is intended to be the active side of the PV device or PV cell, or that is intended to be the electricity-generating side or surface that would generated electricity based on incoming sunlight or light or based on the PV effect; but rather, those non-transcending gaps or the “blind gaps” or craters or slits or grooves are formed at the other (e.g., opposite, non-active) side or surface, which is the side that is not intended to be facing the sunlight or the light, or the side that is not intended to be producing electricity based on the PV effect. Some implementations with this structure may advantageously provide the mechanical shock absorption and the mechanical forces dissipation capability, yet may also provide or maintain or achieve an increased level of PV-based electricity production since the gaps do not reduce the area of the light-exposed side or the light-facing side of the PV device. [0076] In still other embodiments, the non-transcending gaps or the “blind gaps” or craters or slits or trenches or grooves, are introduced and are formed at both sides or at both surfaces of the semiconductor substrate or body or wafer; yet with an offset among the gaps of the first side and the gaps of the second side, in a zig-zag pattern of those gaps which zig-zag across the two sides of the semiconductor wafer or substrate or body; for example, a first gap located at the top surface on the left; then, a second gap located at the bottom surface to the right side of the first gap and not overlapping at all with the first gap; then, a third gap located at the top surface to the right side of the second gap and not overlapping at all with the second gap; then, a fourth gap located at the bottom surface to the right side of the third gap and not overlapping at all with the third gap; and so forth. In such structure, for example, any single point or any single location or any single region of the remaining semiconductor wafer or substrate or wafer, may have a gap or a crater or a “blind gap” only on one of its two sides, but not on both of its sides.

[0077] In yet other embodiments, the non-transcending gaps or the “blind gaps” or craters or slits or grooves, are introduced and are formed at both sides or at both surfaces of the semiconductor substrate or body or wafer; not necessarily with an offset among the gaps of the first side and the gaps of the second side, and not necessarily in a zig-zag pattern; but rather, by implementing any other suitable structure or pattern that still provides the mechanical shock resilience, and while also maintaining a sufficiently-thin layer of semiconductor substrate or body or wafer that is not removed and that is resilient to mechanical shocks and mechanical forces due to the craters or gaps that surround it.

[0078] Some embodiments may include and/or may utilize one or more units, devices, connectors, wires, electrodes, and/or methods which are described in United States patent application publication number US 2016/0308155 Al, which is hereby incorporated by reference in its entirety. For example, some embodiments may include and may utilize an electrode arrangement which is configured to define or create a plurality of electricity collection regions, such that within each of the collection regions, at least two sets of conducting wires are provided such that they are insulated from each other, and the at least two sets of conducting wires are connected either in parallel or in series between the collection regions to thus provide accumulating voltage of charge collection. Some embodiments may include an electric circuit for reading-out or collection or aggregation of the generated electricity, configured as an electrode arrangement, including conducting wires arranged in the form of nets covering zones of a pre-determined area. The electrodes arrangement may be configured or structured to be stretched (e.g., rolled out) along the surface of the PV cell, and may be formed by at least two sets of conducting wires, and may cover a plurality of collection zones or collection regions.

[0079] Within each of the electricity collection zones or electricity aggregation zones, the different conducting wires are insulated from each other, to provide a certain voltage between them. At a transition between zones, the negative charges collecting conductive wire of one zone, is electrically connected to the positive charges collecting conductive wire of the adjacent or the consecutive zone. Thus, within each of the collection zones, the different sets of conducting wires are insulated from each other, while being connected in series between the zones. This configuration of the electrode arrangement allows accumulation or aggregation of electric voltage generated by charge collection along the surface of the PV device. The configuration of the electrode arrangement provides a robust electric collection structure.

[0080] The internal connections between the sets of conducting wires allow energy collection even if the surface being covered is not continuous, e.g., if a perforation occurs in the structure of the net. This feature of the electrode arrangement allows for using this technique on any surface exposed to photon radiation, while also allowing discontinuity if needed and without limiting or disrupting the electric charge collection.

[0081] For demonstrative purposes, some portions of the discussion relate to utilization of the flexible polyimide film (or strips, or bands, or straps, or surfaces) as part of a stand-alone solar panel or as part of a vehicular component or a vehicle; however, some embodiments may similarly provide a solution that can be utilized with, or in, or in conjunction with, other objects or articles or structures; for example, a roof, a roof shingle, a wall, a panel, a side -panel, a horizontal panel, a vertical panel, a slanted panel, an aircraft part, an aircraft, a drone part, a drone, a spacecraft part, a spacecraft, a marine vessel part, a marine vessel, a boat, a ship, a yacht, a floating device, a swimming pool cover or a lake cover, a submarine vessel part, a submarine vessel, a construction equipment or vehicle or agricultural machinery (e.g., bulldozer, tractor, harvester, cotton collector, crane), a bus-stop roof or structure, a gazebo roof, a patio roof, an awning, a greenhouse, a parking spot cover or a parking lot cover, a playground cover, a stadium cover or roof, a shed or a toolshed, a road divider, a road sign, a billboard, a shipping container (e.g., enabling the integration of the solar panel in a roof or side -panel of a shipping container, to provide electric power to electric devices within the container and/or to cooling systems or fans that can cool or can reduce the temperature of top-layer containers on ships), and/or other suitable objects or structures. [0082] The term “vehicle” as used herein may comprise, for example, a car, a sedan car, a sport utility vehicle (SUV), a truck, a bus, a van, a minivan, a train, a wagon of a train, a car of a train, a military vehicle (e.g., a tank, an armored fighting vehicle (AFV), a combat vehicle, or the like), a first responder or law enforcement vehicle (e.g., police car, ambulance, firetruck), a cargo vehicle, a trailer, a mini-trailer, a vehicle for transporting persons and/or animals and/or other cargo, an agricultural vehicle or mobile agricultural equipment (e.g., a tractor, a combine harvester, a cotton harvester, a harvester, a crop sprayer, a hay baler, or the like), a vehicle having a generally flat roof, a vehicle having a curved roof, an autonomous car or vehicle, a self-driving car or vehicle, a remote-controlled car or vehicle, a remotely-controlled car or vehicle, an Electric Vehicle (EV), an Electric Utility Vehicle (EUV), an Internal Combustion Engine (ICE) vehicle or a gasoline vehicle that utilizes the solar panel to recharge its battery and/or to provide power to devices within the vehicle, a hybrid vehicle, or the like.

[0083] Some embodiments provide a production system for mass production of a plurality of discrete composite articles; wherein each composite article comprises an operable photovoltaic cell that is integrally incorporated in a molded component. The production system comprises: (a) a plurality of mold plates, that are stacked on top of each other or that are arranged next to each other; wherein each pair of neighboring mold plates, defines a respective mold cavity; wherein the plurality of mold plates defines a plurality of discrete mold cavities that together are a multi-cavity multi-layer mold structure; (b) a plurality of operable photovoltaic cells, wherein each operable photovoltaic cell is configured for placement as an insert within one of said plurality of discrete mold cavities; (c) one or more reinforcement materials, configured for placement above and/or beneath each operable photovoltaic device within a respective mold cavity; (d) an alignment mechanism, to align the plurality of mold plates and to mechanically maintain the mold plates in place; (e) a plurality of injection ports, wherein each injection port is configured to provide a molding material into one of the discrete mold cavities; (f) an injector unit, configured to inject said molding material at a heated or molten state, at a particular pressure, simultaneously into said plurality of discrete mold cavities of said multi-cavity multi-layer mold structure, through said plurality of injection ports.

[0084] In some embodiments, the injector unit is configured to inject liquid resin and/or heated resin and/or molten resin, simultaneously into said plurality of discrete mold cavities of said multi-cavity multi-layer mold structure.

[0085] In some embodiments, the injector unit is configured to inject liquid resin and/or heated resin and/or molten resin, simultaneously into said plurality of discrete mold cavities of said multi-cavity multi-layer mold structure, in a high-pressure resin transfer molding (HP- RTM) process at an injection pressure in a range of 10 to 150 bars.

[0086] In some embodiments, the injector unit is configured to inject liquid resin and/or heated resin and/or molten resin, simultaneously into said plurality of discrete mold cavities of said multi-cavity multi-layer mold structure, in a low-pressure resin transfer molding (LP- RTM) process at an injection pressure in a range of 4 to 10 bars.

[0087] In some embodiments, the injector unit is configured to inject liquid resin and/or heated resin and/or molten resin, simultaneously into said plurality of discrete mold cavities of said multi-cavity multi-layer mold structure, in a light resin transfer molding (LRTM) process; wherein some of the mold plates are rigid A-type mold plates; wherein some other of the mold plates are semi-rigid B-type mold plates.

[0088] In some embodiments, the injector unit is configured to inject liquid resin and/or heated resin and/or molten resin, simultaneously into said plurality of discrete mold cavities of said multi-cavity multi-layer mold structure, in a Vacuum Assisted resin transfer molding (VA- RTM) process or a Vacuum Injected Molding (VIM) process or a Vacuum Assisted Resin Infusion (VARI) molding process.

[0089] In some embodiments, at least some of the mold plates have a non-planar inner side, which has protrusions that form respective craters in a resulting molded article.

[0090] In some embodiments, at least some of the mold plates have a non-planar inner side, which has craters that form respective protrusions in a resulting molded article.

[0091] In some embodiments, at least some of the mold plates have a flat planar inner side, and form a resulting molded article that has at least some flat planar surfaces.

[0092] In some embodiments, all the mold plates have flat planar inner sides, and form a resulting molded article that has surfaces that are all planar.

[0093] In some embodiments, the plurality of mold plates comprises at least: a first mold plate, stacked on top of a second mold plate, stacked on top of a third mold plate; wherein the first mold plate and the second mold plate define a first mold cavity; wherein the second mold plate and the third mold plate define a second mold cavity; wherein the first mold cavity and the second mold cavity are separate cavities that are not interconnected.

[0094] In some embodiments, the injector unit is configured to inject liquid resin and/or heated resin and/or molten resin that is selected from the group consisting of: epoxy, polyurethane, polyester, or a combination of two or more of these materials. [0095] In some embodiments, the reinforcement materials include at least one of: glass, fiber glass, glass fiber, carbon, carbon fiber, basalt, flax, aramid, natural fibers, fabric; or a combination of two or more of these materials.

[0096] In some embodiments, the mold plates are stacked on top of each other, and are generally parallel to each other.

[0097] In some embodiments, the mold plates are arranged next to each other, and are generally parallel to each other.

[0098] In some embodiments, each of the operable photovoltaic cells is flexible and rollable and foldable and non-brittle; and includes a semiconductor wafer having nontranscending craters that penetrate into 75 to 99 percent of a thickness of the semiconductor wafer, wherein a thin portion of the semiconductor wafer remains intact and non-penetrated, wherein said non-transcending craters dissipate and absorb mechanical forces applied to the operable photovoltaic cell. In some embodiments, the non-transcending craters in the semiconductor wafer of the operable photovoltaic cell contain a filler material that further dissipates and absorbs mechanical forces. In some embodiments, the non-transcending craters in the semiconductor wafer of the operable photovoltaic cell contain a filler material, which comprises at least an elastomer, that further dissipates and absorbs mechanical forces.

[0099] Some embodiments provide a composite article produced by the production system described above; wherein the composite article is an operable photovoltaic device having a molded structure with an integrally incorporated operable photovoltaic cell. In some embodiments, the composite article is a roof or a roof-part or a shingle, having the operable photovoltaic device integrated therein. In some embodiments, the composite article is a tile or a sidewalk tile or a wall tile, having the operable photovoltaic device integrated therein. In some embodiments, the composite article is a vehicular part, having the operable photovoltaic device integrated therein. In some embodiments, the composite article the composite article is capable of autonomously floating on water or sea water or salt water or in a body of water (e.g., pool, lake, sea), as it is structured to have a specific weight that is smaller than one.

[00100] Some embodiments provide a production method for mass production of a plurality of discrete composite articles, wherein each composite article comprises an operable photovoltaic cell that is integrally incorporated in a molded component. For example, the production method comprises: (a) providing and/or placing and/or mounting and/or stacking and/or arranging a plurality of mold plates, that are stacked on top of each other or that are arranged next to each other; wherein each pair of neighboring mold plates, defines a respective mold cavity; wherein the plurality of mold plates defines a plurality of discrete mold cavities that together are a multi-cavity multi-layer mold structure; (b) providing and/or inserting a plurality of operable photovoltaic cells, wherein each operable photovoltaic cell is configured for placement as an insert within one of said plurality of discrete mold cavities; (c) providing and/or inserting one or more reinforcement materials, configured for placement above and/or beneath each operable photovoltaic device within a respective mold cavity; (d) providing and/or operating and/or configuring an alignment mechanism, to align the plurality of mold plates and to mechanically maintain the mold plates in place; (e) providing or configuring or opening or deploying a plurality of injection ports, wherein each injection port is configured to provide a molding material into one of the discrete mold cavities; (f) configuring and/or operating and/or triggering and/or controlling and/or starting an injector unit, configured to inject said molding material at a liquid and/or heated and/or molted state, at a particular pressure, simultaneously into said plurality of discrete mold cavities of said multi-cavity multilayer mold structure, through said plurality of injection ports. Some embodiments provide a composite article produced by the production method described above; wherein the composite article is an operable photovoltaic device having a molded structure with an integrally incorporated operable photovoltaic cell.

[00101] The terms “plurality” and “a plurality”, as used herein, include, for example, “multiple” or “two or more”. For example, “a plurality of items” includes two or more items. [00102] References to “one embodiment”, “an embodiment”, “demonstrative embodiment”, “various embodiments”, “some embodiments”, and/or similar terms, may indicate that the embodiment(s) so described may optionally include a particular feature, structure, or characteristic, but not every embodiment necessarily includes the particular feature, structure, or characteristic. Furthermore, repeated use of the phrase “in one embodiment” does not necessarily refer to the same embodiment, although it may. Similarly, repeated use of the phrase “in some embodiments” does not necessarily refer to the same set or group of embodiments, although it may.

[00103] As used herein, and unless otherwise specified, the utilization of ordinal adjectives such as “first”, “second”, “third”, “fourth”, and so forth, to describe an item or an object, merely indicates that different instances of such like items or objects are being referred to; and does not intend to imply as if the items or objects so described must be in a particular given sequence, either temporally, spatially, in ranking, or in any other ordering manner.

[00104] Functions, operations, components and/or features described herein with reference to one or more embodiments, may be combined with, or may be utilized in combination with, one or more other functions, operations, components and/or features described herein with reference to one or more other embodiments. Some embodiments may thus comprise any possible or suitable combinations, re-arrangements, assembly, re-assembly, or other utilization of some or all of the modules or functions or components that are described herein, even if they are discussed in different locations or different chapters of the above discussion, or even if they are shown across different drawings or multiple drawings.

[00105] While certain features of some demonstrative embodiments have been illustrated and described herein, various modifications, substitutions, changes, and equivalents may occur to those skilled in the art. Accordingly, the claims are intended to cover all such modifications, substitutions, changes, and equivalents.

Claims

1. A production system for mass production of a plurality of discrete composite articles, wherein each composite article comprises an operable photovoltaic cell that is integrally incorporated in a molded component, wherein the production system comprises:

(a) a plurality of mold plates, that are stacked on top of each other or that are arranged next to each other; wherein each pair of neighboring mold plates, defines a respective mold cavity; wherein the plurality of mold plates defines a plurality of discrete mold cavities that together are a multi-cavity multi-layer mold structure;

(b) a plurality of operable photovoltaic cells, wherein each operable photovoltaic cell is configured for placement as an insert within one of said plurality of discrete mold cavities;

(c) one or more reinforcement materials, configured for placement above and/or beneath each operable photovoltaic device within a respective mold cavity;

(d) an alignment mechanism, to align the plurality of mold plates and to mechanically maintain the mold plates in place;

(e) a plurality of injection ports, wherein each injection port is configured to provide a molding material into one of the discrete mold cavities;

(f) an injector unit, configured to inject said molding material at a heated or molten state, at a particular pressure, simultaneously into said plurality of discrete mold cavities of said multi-cavity multi-layer mold structure, through said plurality of injection ports.

2. The production system according to claim 1, wherein the injector unit is configured to inject liquid resin and/or heated resin and/or molten resin, simultaneously into said plurality of discrete mold cavities of said multi-cavity multi-layer mold structure.

3. The production system according to claim 1, wherein the injector unit is configured to inject liquid resin and/or heated resin and/or molten resin, simultaneously into said plurality of discrete mold cavities of said multi-cavity multi-layer mold structure, in a high-pressure resin transfer molding (HP-RTM) process at an injection pressure in a range of 10 to 150 bars.

4. The production system according to claim 1 , wherein the injector unit is configured to inject liquid resin and/or heated resin and/or molten resin, simultaneously into said plurality of discrete mold cavities of said multi-cavity multi-layer mold structure, in a low-pressure resin transfer molding (LP-RTM) process at an injection pressure in a range of 4 to 10 bars.

5. The production system according to claim 1, wherein the injector unit is configured to inject liquid resin and/or heated resin and/or molten resin, simultaneously into said plurality of discrete mold cavities of said multi-cavity multi-layer mold structure, in a light resin transfer molding (LRTM) process; wherein some of the mold plates are rigid A-type mold plates; wherein some other of the mold plates are semi-rigid B-type mold plates.

6. The production system according to claim 1, wherein the injector unit is configured to inject liquid resin and/or heated resin and/or molten resin, simultaneously into said plurality of discrete mold cavities of said multi-cavity multi-layer mold structure, in a Vacuum Assisted resin transfer molding (VA-RTM) process or a Vacuum Injected Molding (VIM) process or a Vacuum Assisted Resin Infusion (VARI) molding process.

7. The production system according to any one of claims 1-6, wherein at least some of the mold plates have a non-planar inner side, which has protrusions that form respective craters in a resulting molded article.

8. The production system according to any one of claims 1-7, wherein at least some of the mold plates have a non-planar inner side, which has craters that form respective protrusions in a resulting molded article.

9. The production system according to any one of claims 1-6, wherein at least some of the mold plates have a flat planar inner side, and form a resulting molded article that has at least some flat planar surfaces.

10. The production system according to any one of claims 1-6, wherein all the mold plates have flat planar inner sides, and form a resulting molded article that has surfaces that are all planar.

11. The production system according to any one of claims 1-10, wherein the plurality of mold plates comprises at least: a first mold plate, stacked on top of a second mold plate, stacked on top of a third mold plate; wherein the first mold plate and the second mold plate define a first mold cavity; wherein the second mold plate and the third mold plate define a second mold cavity; wherein the first mold cavity and the second mold cavity are separate cavities that are not interconnected.

12. The production system according to any one of claims 1-11, wherein the injector unit is configured to inject liquid resin and/or heated resin and/or molten resin that is selected from the group consisting of: epoxy, polyurethane, polyester, or a combination of two or more of these materials.

13. The production system according to any one of claims 1-12, wherein the reinforcement materials include at least one of: glass, fiber glass, glass fiber, carbon, carbon fiber, basalt, flax, aramid, natural fibers, fabric.

14. The production system according to any one of claims 1-13, wherein the mold plates are stacked on top of each other, and are generally parallel to each other.

15. The production system according to any one of claims 1-13, wherein the mold plates are arranged next to each other, and are generally parallel to each other.

16. The production system according to any one of claims 1-15, wherein each of the operable photovoltaic cells is flexible and rollable and foldable and non-brittle.

17. The production system according to any one of claims 1-15, wherein each of the operable photovoltaic cells is flexible and rollable and foldable and non-brittle, and includes a semiconductor wafer having non-transcending craters that penetrate into 75 to 99 percent of a thickness of the semiconductor wafer, wherein a thin portion of the semiconductor wafer remains intact and non-penetrated, wherein said non-transcending craters dissipate and absorb mechanical forces applied to the operable photovoltaic cell.

18. The production system according to claim 17, wherein the non-transcending craters in the semiconductor wafer of the operable photovoltaic cell contain a filler material that further dissipates and absorbs mechanical forces.

19. The production system according to claim 17, wherein the non-transcending craters in the semiconductor wafer of the operable photovoltaic cell contain a filler material, which comprises at least an elastomer, that further dissipates and absorbs mechanical forces.

20. A composite article produced by the production system of any one of claims 1-19, wherein the composite article is an operable photovoltaic device having a molded structure with an integrally incorporated operable photovoltaic cell.

21. The composite article of claim 20, wherein the composite article is a roof or a roof-part or a shingle, having the operable photovoltaic device integrated therein.

22. The composite article of claim 20, wherein the composite article is a tile or a sidewalk tile or a wall tile, having the operable photovoltaic device integrated therein.

23. The composite article of claim 20, wherein the composite article is a vehicular part, having the operable photovoltaic device integrated therein.

24. The composite article of claim 20, wherein the composite article is capable of autonomously floating on water.

25. A production method for mass production of a plurality of discrete composite articles, wherein each composite article comprises an operable photovoltaic cell that is integrally incorporated in a molded component, wherein the production method comprises:

(a) providing a plurality of mold plates, that are stacked on top of each other or that are arranged next to each other; wherein each pair of neighboring mold plates, defines a respective mold cavity; wherein the plurality of mold plates defines a plurality of discrete mold cavities that together are a multi-cavity multi-layer mold structure;

(b) providing a plurality of operable photovoltaic cells, wherein each operable photovoltaic cell is configured for placement as an insert within one of said plurality of discrete mold cavities;

(c) providing one or more reinforcement materials, configured for placement above and/or beneath each operable photovoltaic device within a respective mold cavity;

(d) providing an alignment mechanism, to align the plurality of mold plates and to mechanically maintain the mold plates in place;

(e) providing a plurality of injection ports, wherein each injection port is configured to provide a molding material into one of the discrete mold cavities;

(f) operating an injector unit, configured to inject said molding material at a liquid and/or heated and/or molted state, at a particular pressure, simultaneously into said plurality of discrete mold cavities of said multi-cavity multi-layer mold structure, through said plurality of injection ports.

26. A composite article produced by the production method of claim 25, wherein the composite article is an operable photovoltaic device having a molded structure with an integrally incorporated operable photovoltaic cell.