Solar car

• US 10,457,148 B2
• Filed: 04/16/2018
• Issued: 10/29/2019
• Est. Priority Date: 02/24/2017
• Status: Active Grant

• Current Assignee: Epic Battery, Inc.
• Original Assignee: Epic Battery, Inc.
• Inventors: Bullen, Melvin James
• Primary Examiner(s): Mowla, Golam
• Application Number:
  US15/954,408
• Publication Number:
  US 20180244160A1
• Time in Patent Office: 561 Days
• CPC Class Codes: B60K 16/00 Arrangements in connection with power supply of propulsion units in vehicles from forces of nature, e.g. sun or wind electric propulsion with power supply from forces of nature, e.g. sun or wind B60L8/00; marine propulsion by wind motors driving water-engaging propulsive elements B63H13/00; wind motors specially adapted for installation on vehicles F03D9/32
• CPC Class Codes: B60K 2016/003 solar power driven
• CPC Class Codes: B60L 15/20 for control of the vehicle or its driving motor to achieve a desired performance, e.g. speed, torque, programmed variation of speed
• CPC Class Codes: B60L 2210/10 DC to DC converters
• CPC Class Codes: B60L 2220/50 Structural details of electrical machines
• CPC Class Codes: B60L 2240/421 Speed
• CPC Class Codes: B60L 2240/423 Torque
• CPC Class Codes: B60L 50/53 in combination with an external power supply, e.g. from overhead contact lines
• CPC Class Codes: B60L 8/003 Converting light into electric energy, e.g. by using photo-voltaic systems
• CPC Class Codes: G05F 1/67 to the maximum power available from a generator, e.g. from solar cell
• CPC Class Codes: H01L 31/022425 for solar cells
• CPC Class Codes: H01L 31/035281 Shape of the body
• CPC Class Codes: H01L 31/0468 comprising specific means for obtaining partial light transmission through the module, e.g. partially transparent thin film solar modules for windows
• CPC Class Codes: H01L 31/048 Encapsulation of modules
• CPC Class Codes: H01L 31/0481 characterised by the composition of the encapsulation material
• CPC Class Codes: H01L 31/18 Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
• CPC Class Codes: H02J 2310/40 The network being an on-board power network, i.e. within a vehicle
• CPC Class Codes: H02J 7/35 with light sensitive cells
• CPC Class Codes: H02K 1/02 characterised by the magnetic material
• CPC Class Codes: H02K 1/141 consisting of C-shaped cores
• CPC Class Codes: H02K 1/2753 : the rotor consisting of magnets or groups of magnets arranged with alternating polarity
• CPC Class Codes: H02K 11/0094 : Structural association with other electrical or electronic devices
• CPC Class Codes: H02K 11/33 : Drive circuits, e.g. power electronics H02K11/38 takes precedence
• CPC Class Codes: H02K 3/521 : applicable to stators only
• CPC Class Codes: H02K 5/06 : Cast metal casings
• CPC Class Codes: H02K 7/09 : with magnetic bearings
• CPC Class Codes: H02S 10/40 : Mobile PV generator systems
• CPC Class Codes: H02S 20/30 : Supporting structures being movable or adjustable, e.g. for angle adjustment
• CPC Class Codes: H02S 40/38 : Energy storage means, e.g. batteries, structurally associated with PV modules
• CPC Class Codes: H10K 30/88 : Passivation; Containers; Encapsulations
• CPC Class Codes: Y02E 10/50 : Photovoltaic [PV] energy
• CPC Class Codes: Y02E 10/56 : Power conversion systems, e.g. maximum power point trackers
• CPC Class Codes: Y02E 70/30 : Systems combining energy storage with energy generation of non-fossil origin
• CPC Class Codes: Y02T 10/64 : Electric machine technologies in electromobility
• CPC Class Codes: Y02T 10/70 : Energy storage systems for electromobility, e.g. batteries
• CPC Class Codes: Y02T 10/7072 : Electromobility specific charging systems or methods for batteries, ultracapacitors, supercapacitors or double-layer capacitors
• CPC Class Codes: Y02T 10/72 : Electric energy management in electromobility
• CPC Class Codes: Y02T 10/90 : Energy harvesting concepts as power supply for auxiliaries' energy consumption, e.g. photovoltaic sun-roof

Abstract

Described herein are apparatuses, systems, and methods for a solar car. The exterior of the solar car is comprised of smoothly curved and continuous photovoltaic cells. The exterior car parts, e.g., roof, doors, hood, trunk and so forth, may include integrated photovoltaic cells, all manufactured in the shape of the corresponding car parts. The photovoltaic cells are meta-encapsulated in an edgeless manner, and may utilize superconducting anodes. A first encapsulate may be polychlorotrifluoroethylene, an extreme water barrier. A second encapsulate, e.g., silicone, may be a water barrier and shock absorber. A third encapsulate may be UV stabilized polycarbonate or low iron glass. A street legal solar car may be constructed upon an electric car chassis. A competition solar car has one or more hyper-efficient electric motors, that may utilize superconducting wire in their armatures. Superconducting wire may also be used in the vehicle chassis.

Claims

1. A solar car comprising:

a structural frame;

an electric motor;

a battery to power the electric motor; and

a solar car panel coupled to the structural frame, the solar car panel forming an exterior surface of the solar car, and the solar car panel including;

a solar cell to charge the battery, wherein the solar cell has a three-dimensional shape that corresponds to the exterior surface of the solar car;

a first encapsulant layer that at least partially encapsulates the solar cell, wherein the first encapsulant layer includes polychlorotrifluoroethylene (PCTFE);

a second encapsulant layer on the first encapsulant layer, wherein the second encapsulant layer at least partially encapsulates the solar cell, and wherein the second encapsulant layer includes silicone; and

a third encapsulant layer on the second encapsulant layer, wherein the third encapsulant layer at least partially encapsulates the solar cell, and wherein the third encapsulant layer includes glass.

2. The solar car of claim 1, wherein the solar car panel is a hood, roof, a trunk, or a door of the solar car, and wherein the three-dimensional shape of the solar panel corresponds to a shape of the respective hood, roof, trunk, or door.

3. The solar car of claim 1, wherein the third encapsulant layer includes a first portion of low iron glass and a second portion of structural glass coupled together by a microelectromechanical systems (MEMS) bond, wherein the first portion faces the exterior surface and wherein the second portion faces an interior region of the solar car.

4. The solar car of claim 1, wherein the third encapsulant layer partially encapsulates the solar cell to leave an interior side of the second encapsulant layer exposed, and wherein the solar car panel further includes:

a support structure coupled to the interior side of the second encapsulant layer by an adhesive and bonded to the third encapsulant layer by a microelectromechanical systems (MEMS) bond.

5. The solar car of claim 1, further comprising a window coupled to the solar car panel, wherein the window includes a solar cell having a transparent thin-film photovoltaic material.

6. The solar car of claim 5, wherein the solar car panel corresponds to a door of the solar car, and wherein the window is configured to move relative to the door.

7. The solar car of claim 5, wherein the window corresponds to a windshield of the solar car, and wherein the window further includes a tinted region that includes a tandem solar cell formed by the transparent thin-film photovoltaic material and a perovskite.

8. The solar car of claim 1, further comprising a direct current (DC) power converter coupled to the solar cell to set the solar cell at a maximum power point and derive a DC output power signal from the solar cell.

9. The solar car of claim 8, further comprising a power combiner to:

receive the DC output power signal;

combine the DC output power signal with another DC output power signal from one or more other solar car panels of the solar car; and

pass the combined DC output power signal to the battery to charge the battery.

10. The solar car of claim 1, wherein the second encapsulant layer is thicker on an interior side of the solar cell that faces an interior of the solar car than on an exterior side of the solar cell that faces the exterior surface of the solar car.

11. The solar car of claim 1, further comprising:

an anode wire coupled to an anode of the solar cell; and

a cathode wire coupled to a cathode of the solar cell;

wherein the anode wire and cathode wire extend through an opening in the third encapsulant layer, and wherein the opening is filled with a fill material that is different from respective materials of the second and third encapsulant layers.

12. The solar car of claim 11, wherein the fill material is sodium silicate.

13. The solar car of claim 1, wherein the first, second, and third encapsulant layers fully encapsulate the solar cell.

22. The solar car of claim 13, further comprising a direct current (DC) power converter coupled to the solar cell to set the solar cell at a maximum power point and derive a DC output power signal from the solar cell.

23. The solar car of claim 22, further comprising a power combiner to:

receive the DC output power signal;

combine the DC output power signal with another DC output power signal from one or more other solar car panels of the solar car; and

pass the combined DC output power signal to the battery to charge the battery.

14. A solar car comprising:

a structural frame;

an electric motor;

a battery to power the electric motor; and

a solar car panel coupled to the structural frame, the solar car panel forming an exterior surface of the solar car, and the solar car panel including;

a solar cell to charge the battery, wherein the solar cell has a three-dimensional shape that corresponds to the exterior surface of the solar car;

a first encapsulant layer that at least partially encapsulates the solar cell;

a second encapsulant layer on the first encapsulant layer, wherein the second encapsulant layer at least partially encapsulates the solar cell;

a third encapsulant layer on the second encapsulant layer, wherein the third encapsulant layer at least partially encapsulates the solar cell;

an anode wire coupled to an anode of the solar cell; and

a cathode wire coupled to a cathode of the solar cell;

wherein the anode wire and cathode wire extend through an opening in the third encapsulant layer, and wherein the opening is filled with a fill material that is different from respective materials of the second and third encapsulant layers.

15. The solar car of claim 14, wherein the fill material is sodium silicate.

16. The solar car of claim 14, wherein the solar car panel is a hood, roof, a trunk, or a door of the solar car, and wherein the three-dimensional shape of the solar panel corresponds to a shape of the respective hood, roof, trunk, or door.

17. The solar car of claim 14, wherein the third encapsulant layer includes a first portion of low iron glass and a second portion of structural glass coupled together by a microelectromechanical systems (MEMS) bond, wherein the first portion faces the exterior surface and wherein the second portion faces an interior region of the solar car.

18. The solar car of claim 14, wherein the third encapsulant layer partially encapsulates the solar cell to leave an interior side of the second encapsulant layer exposed, and wherein the solar car panel further includes:

a support structure coupled to the interior side of the second encapsulant layer by an adhesive and bonded to the third encapsulant layer by a microelectromechanical systems (MEMS) bond.

19. The solar car of claim 14, further comprising a window coupled to the solar car panel, wherein the window includes a solar cell having a transparent thin-film photovoltaic material.

20. The solar car of claim 19, wherein the solar car panel corresponds to a door of the solar car, and wherein the window is configured to move relative to the door.

21. The solar car of claim 19, wherein the window corresponds to a windshield of the solar car, and wherein the window further includes a tinted region that includes a tandem solar cell formed by the transparent thin-film photovoltaic material and a perovskite.

24. The solar car of claim 14, wherein the second encapsulant layer is thicker on an interior side of the solar cell that faces an interior of the solar car than on an exterior side of the solar cell that faces the exterior surface of the solar car.

25. A solar car comprising:

a structural frame;

an electric motor, wherein the electric motor includes;

an outer ring having electromagnets;

an inner ring having permanent magnets;

a conductive wire coupled between the battery and the electromagnets to activate the electromagnets and thereby drive the motor, wherein the conductive wire includes a plurality of conductive strands, and wherein individual strands of the plurality of conductive strands include;

a first layer and a second layer coupled to one another, wherein the first layer and second layer are atomic or molecular monolayers and at least one of the first layer or second layer has a hexagonal atomic or molecular structure; and

an first insulating layer on the first layer, the first insulating layer is a first insulating material;

a second insulating layer on the second layer, wherein the second insulating layer is the first insulating material or a second insulating material; and

a coating material surrounding the first layer, the second layer, the first insulating layer, and the second insulating layer;

a battery to power the electric motor; and

a solar car panel coupled to the structural frame, the solar car panel forming an exterior surface of the solar car, and the solar car panel including a solar cell to charge the battery.

26. The solar car of claim 25, wherein:

the first layer is graphene;

the second layer is tin;

the first insulating material is aluminum oxide (Al₂O₃); and

the second insulating material is aluminum oxide or methyl (CH₄).

27. The solar car of claim 25, wherein the electromagnets include amorphous nickel and the permanent magnets include neodymium iron boron.

28. The solar car of claim 25, further comprising control circuitry coupled to the electromagnets via the conductive wire, the control circuitry including:

a first control loop to control the electric motor based on at least one of velocity and torque feedback; and

a second control loop to sense a current draw of the electric motor and limit the current draw to below a threshold.

29. The solar car of claim 25, wherein the solar cell has a three-dimensional shape that corresponds to the exterior surface of the solar car, and wherein the solar car panel further includes:

a first encapsulant layer that at least partially encapsulates the solar cell;

a second encapsulant layer on the first encapsulant layer, wherein the second encapsulant layer at least partially encapsulates the solar cell; and

a third encapsulant layer on the second encapsulant layer, wherein the third encapsulant layer at least partially encapsulates the solar cell.