Stratospheric vehicles with integrated flexible solar cell material and method of production

Abstract

A novel energy producing flexible material is provided particularly suited for high altitude and stratospheric applications. The flexible energy producing covering includes a flexible solar cell layer, a flexible substrate which preferably matches the shape and size of the airship gore as well and an electrically conductive conduit disposed in a flexible electrically non-conductive adhesive connecting the flexible solar cell substrate to the airship substrate. Preferably two electrically conductive conduits are provided between the substrate layer and the flexible solar cell layer with the electrically conductive conduits being insulated from one another by the non-conductive adhesive. The novel process provided by the invention for joining the airship substrate to the flexible solar cell substrate includes heat, pressure and the selection of substrate materials and in certain applications the use of a vacuum.

What is claimed is:  
     
         1 . A vehicle having a flexible energy producing covering comprising: 
 (a) a layer of flexible solar cells deposited on a flexible substrate;    (b) a flexible substrate;    (c) a non-conductive flexible adhesive bonding said flexible substrate to said polymer substrate;    (d) an electrically conductive conduit disposed intermediate said flexible substrate and said layer of flexible solar cells.    
     
     
         2 . The vehicle of  claim 1  further comprising a second electrically conductive conduit disposed intermediate said flexible substrate and said layer of flexible solar cells.  
     
     
         3 . The vehicle of  claim 2  wherein said flexible substrate is gas pervious.  
     
     
         4 . The vehicle of  claim 3  wherein said flexible substrate is a fabric substrate of an airship and said first electrically conductive conduit is a plurality of electrically conductive warp threads disposed substantially along the entire length of said airship.  
     
     
         5 . The vehicle of  claim 4  wherein the weft threads of said fabric substrate are electrically non-conductive.  
     
     
         6 . The vehicle of  claim 5  wherein said second electrically conductive conduit is a second plurality of warp threads disposed adjacent to said plurality of electrically conductive warp threads and electrically insulated from said second plurality of warp threads by said weft threads.  
     
     
         7 . The vehicle of  claim 6  wherein the airship energy producing covering is about 200 to 800 microns thick.  
     
     
         8 . The vehicle of  claim 7  wherein said plurality of warp threads are capable of carrying a voltage of from about 40 to 6,000 volts.  
     
     
         9 . The vehicle of  claim 6  wherein said airship energy producing covering is about 50 to 350 meters long and about 1 to 150 meters wide.  
     
     
         10 . The vehicle of  claim 5  wherein said second electrically conductive conduit is a conductive ribbon disposed between said fabric substrate and said layer of flexible solar cells.  
     
     
         11 . The vehicle of  claim 10  wherein said conductive ribbon is disposed between said non-conductive flexible adhesive and said layer of flexible solar cells.  
     
     
         12 . The vehicle of  claim 10  wherein said conductive ribbon is from about 10 to 100 microns thick and from about 12 to 30 centimeters wide.  
     
     
         13 . The vehicle of  claim 12  wherein said conductive ribbon is disposed substantially along the entire length of said airship.  
     
     
         14 . The vehicle of  claim 12  wherein said conductive ribbon is a metallic conductive ribbon.  
     
     
         15 . The vehicle of  claim 2  wherein said flexible substrate is a polymer film.  
     
     
         16 . The vehicle of  claim 15  wherein said substrate is a gas pervious substrate of an airship.  
     
     
         17 . The vehicle of  claim 16  wherein said electrically conductive conduit and said second electrically conductive conduit are a first conductive ribbon and second conductive ribbon.  
     
     
         18 . The vehicle of  claim 17  wherein said first conductive ribbon and said second conductive ribbon are about 10 to 100 microns thick and about 12 to 30 centimeters wide.  
     
     
         19 . The vehicle of  claim 17  wherein said first conductive ribbon and said second conductive ribbon run substantially the entire length of said airship.  
     
     
         20 . The vehicle of  claim 19  wherein said first conductive ribbon and said second conductive ribbon are separated by said non-conductive flexible adhesive in different layers.  
     
     
         21 . The vehicle of  claim 19  wherein said first conductive ribbon and said second conductive ribbon are capable of carrying from about 40 to 6,000 volts.  
     
     
         22 . An energy producing gore for an airship comprising: 
 (a) a layer of flexible solar cells deposited on the outer surface of an airship gore;    (b) a flexible substrate forming the inner surface of said airship gore;    (c) a non-conductive adhesive bonding said flexible substrate to said outer surface;    (d) a first electrically conductive conduit disposed intermediate said layer of flexible solar cells and said flexible substrate; and    (e) a second electrically conductive conduit disposed intermediate said flexible substrate and said layer of flexible solar cells.    
     
     
         23 . The energy producing gore of  claim 22  wherein said flexible substrate is gas pervious.  
     
     
         24 . The energy producing gore of  claim 23  wherein said flexible substrate is fabric and said first electrically conductive conduit is a plurality of first electrically conductive warp threads disposed substantially along the entire length of the gore.  
     
     
         25 . The energy producing gore of  claim 24  wherein the weft threads of said fabric are electrically non-conductive.  
     
     
         26 . The energy producing gore of  claim 25  wherein said second electrically conductive conduit is a second plurality of warp threads disposed adjacent to said plurality of first electrically conductive warp threads and electrically insulated from said first plurality of warp threads by said weft threads.  
     
     
         27 . The energy producing gore of  claim 26  wherein the gore is about 400 to 1,000 microns thick.  
     
     
         28 . The energy producing gore of  claim 26  wherein said gore is about 50 to 350 meters long and about 1 to 10 meters wide.  
     
     
         29 . The energy producing gore of  claim 25  wherein said second electrically conductive conduit is a conductive ribbon disposed between said fabric and said layer of flexible solar cells.  
     
     
         30 . The energy producing gore of  claim 29  wherein said conductive ribbon is disposed between said adhesive and said layer of flexible solar cells.  
     
     
         31 . The energy producing gore of  claim 29  wherein said conductive ribbon is from about 10 to 100 microns thick and from about 12 to 30 centimeters wide.  
     
     
         32 . The energy producing gore of  claim 31  wherein said conductive ribbon is disposed substantially along the entire length of the gore.  
     
     
         33 . The energy producing gore of  claim 31  wherein said conductive ribbon is a metallic conductive ribbon.  
     
     
         34 . The energy producing gore of  claim 22  wherein said flexible substrate is a polymer film.  
     
     
         35 . The energy producing gore of  claim 34  wherein said flexible substrate is gas pervious.  
     
     
         36 . The energy producing gore of  claim 35  wherein said first electrically conductive conduit and said second electrically conductive conduit is a first conductive ribbon and second conductive ribbon.  
     
     
         37 . The energy producing gore of  claim 36  wherein said first conductive ribbon and said second conductive ribbon are about 25 to 100 microns thick and about 12 to 30 centimeters wide.  
     
     
         38 . The energy producing gore of  claim 36  wherein said first conductive ribbon and said second conductive ribbon run substantially the entire length of the gore.  
     
     
         39 . The energy producing gore of  claim 38  wherein said first conductive ribbon and said second conductive ribbon are separated by said non-conductive flexible adhesive in different layers.  
     
     
         40 . A high altitude flexible covering for converting solar energy to electrical energy comprising: 
 (a) a flexible solar cell layer;    (b) a flexible substrate layer;    (c) an electrically non-conductive flexible polymer adhesive bonding said flexible solar cell layer to said flexible substrate layer;    (d) a first electrically conductive conduit disposed intermediate said flexible solar cell layer and said flexible substrate layer and connected to said flexible solar cell layer; and    (e) a second electrically conductive conduit disposed intermediate said flexible solar cell layer and said flexible substrate layer and connected to said flexible solar cell layer.    
     
     
         41 . The high altitude flexible covering of  claim 40  wherein said flexible solar cell layer forms the outer surface of an airship gore.  
     
     
         42 . The high altitude flexible covering of  claim 41  wherein said flexible substrate layer is a fabric material.  
     
     
         43 . The high altitude flexible covering of  claim 42  wherein said electrically conductive conduit is an electrically conductive warp thread in said fabric material.  
     
     
         44 . The high altitude flexible covering of  claim 43  wherein said warp thread extends substantially along the entire length of said airship gore.  
     
     
         45 . The high altitude flexible covering of  claim 44  wherein said fabric material includes electrically non-conductive weft threads.  
     
     
         46 . The high altitude flexible covering of  claim 45  wherein said second electrically conductive conduit extends substantially along the entire length of the airship gore.  
     
     
         47 . The high altitude flexible covering of  claim 46  wherein said second electrically conductive conduit is a metallic ribbon disposed between said electrically non-conductive flexible polymer adhesive.  
     
     
         48 . The high altitude flexible covering of  claim 46  wherein said second electrically conductive conduit is a second electrically conductive warp thread in said fabric material.  
     
     
         49 . The high altitude flexible covering of  claim 42  wherein said flexible substrate layer is gas pervious.  
     
     
         50 . The high altitude flexible covering of  claim 40  wherein said flexible substrate layer is a plastic film.  
     
     
         51 . The high altitude flexible covering of  claim 40  wherein said first electrically conductive conduit and said second electrically conductive conduit extends substantially along the length of an airship gore.  
     
     
         52 . The high altitude flexible covering of  claim 51  wherein said first electrically conductive conduit and said second electrically conductive conduit are about 12 to 30 centimeters wide.  
     
     
         53 . The high altitude flexible covering of  claim 51  wherein said first electrically conductive conduit and said second electrically conductive conduit are electrically isolated by said electrically non-conductive flexible polymer adhesive.  
     
     
         54 . The high altitude flexible covering of  claim 53  wherein said first electrically conductive conduit and said second electrically conductive conduit are electrically isolated in different layers of said electrically non-conductive flexible polymer adhesive.  
     
     
         55 . An energy producing flexible covering comprising: 
 (a) a flexible solar cell;    (b) a flexible substrate;    (c) a non-conductive adhesive bonding said flexible solar cell to said flexible substrate;    (d) a first electrically conductive conduit disposed intermediate said flexible solar cell and said flexible substrate and connected to said flexible solar cell; and    (e) a second electrically conductive conduit disposed intermediate said flexible solar cell and said flexible substrate and connected to said flexible solar cell.    
     
     
         56 . The energy producing flexible covering of  claim 55  wherein said flexible substrate is a fabric material.  
     
     
         57 . The energy producing flexible covering of  claim 56  wherein said first electrically conductive conduit is an electrically conductive thread woven in said fabric material.  
     
     
         58 . The energy producing flexible covering of  claim 57  wherein said second electrically conductive conduit is a second electrically conductive thread woven in said fabric material.  
     
     
         59 . The energy producing flexible covering of  claim 58  further comprising a solar cell protective covering.  
     
     
         60 . The energy producing flexible covering of  claim 57  wherein said second electrically conductive conduit is a metallic ribbon.  
     
     
         61 . The energy producing flexible covering of  claim 60  wherein said metallic ribbon includes an electrically conductive fibrous-like surface.  
     
     
         62 . The energy producing flexible covering of  claim 60  wherein said metallic ribbon is disposed intermediate said flexible solar cell and said fabric material.  
     
     
         63 . The energy producing flexible covering of  claim 62  wherein said metallic ribbon is disposed on the upper surface of said non-conductive adhesive.  
     
     
         64 . The energy producing flexible covering of  claim 62  wherein said non-conductive adhesive includes a plurality of openings.  
     
     
         65 . The energy producing flexible covering of  claim 64  further comprising an electrically conductive material disposed in said plurality of openings to connect said flexible solar cell with said conductive thread.  
     
     
         66 . The energy producing flexible covering of  claim 64  wherein said electrically conductive material is a conductive adhesive.  
     
     
         67 . The energy producing flexible covering of  claim 62  further comprising an electrically conductive material disposed in said plurality of openings to connect said flexible solar cell with said metallic ribbon and to connect said flexible solar cell with said second conductive thread.  
     
     
         68 . The energy producing flexible covering of  claim 55  wherein said flexible substrate is a plastic material.  
     
     
         69 . The energy producing flexible covering of  claim 68  wherein said first conductive conduit is a metallic ribbon.  
     
     
         70 . The energy producing flexible covering of  claim 69  wherein said second conductive conduit is a second metallic ribbon.  
     
     
         71 . The energy producing flexible covering of  claim 70  wherein said metallic ribbon is disposed intermediate said flexible solar cell and said non-conductive adhesive.  
     
     
         72 . The energy producing flexible covering of  claim 71  wherein said second conductive conduit is disposed intermediate said non-conductive adhesive and said flexible substrate.  
     
     
         73 . The energy producing flexible covering of  claim 75  wherein said non-conductive adhesive includes a plurality of openings.  
     
     
         74 . The energy producing flexible covering of  claim 73  further comprising an electrically conductive material in said plurality of openings for connecting said flexible solar cell to said second metallic ribbon.  
     
     
         75 . The energy producing flexible covering of  claim 55  wherein said non-conductive adhesive is a polymer adhesive selected from the group of adhesives consisting of acrylic, silicone, polyurethane and mixtures thereof.  
     
     
         76 . A process for making a flexible energy producing material comprising: 
 (a) aligning a layer of flexible solar cells with a flexible substrate layer;    (b) adding a layer of non-conductive adhesive between said aligned layer of flexible solar cells and said flexible substrate layer; and    (c) heating and pressing said aligned layer of flexible solar cells and said flexible substrate layer to produce a flexible energy producing material.    
     
     
         77 . The process of  claim 76  further comprising the step of providing electrically conductive areas in said layer of non-conductive adhesive.  
     
     
         78 . The process of  claim 77  wherein said step of providing conductive areas is achieved with a gravure roller.  
     
     
         79 . The process of  claim 76  further comprising the step of applying a vacuum during the step of heating and pressing said aligned layer of flexible solar cells and said flexible substrate layer.  
     
     
         80 . The process of  claim 79  wherein said vacuum is about 8 to 45 Torr.  
     
     
         81 . The process of  claim 76  wherein said step of aligning is accomplished by using alignment rollers.  
     
     
         82 . The process of  claim 81  wherein said step of heating and pressing is accomplished with rollers.  
     
     
         83 . The process of  claim 82  wherein said step of heating and pressing is accomplished with a heating roller.  
     
     
         84 . A process for making an energy producing airship gore comprising: 
 (a) depositing flexible solar cells on an airship gore polymer film to produce a solar cell gore layer;    (b) aligning said solar cell gore layer with a substrate gore layer;    (c) adding a layer of a non-conductive adhesive;    (d) introducing a conductive conduit intermediate said solar cell gore and said substrate gore layer; and    (e) heating and pressing said aligned solar cell gore, said substrate gore and said adhesive to produce an energy producing gore.    
     
     
         85 . The product of the process of  claim 84 .  
     
     
         86 . The process of  claim 84  further comprising the step of imparting electrically conductive areas on said layer of non-conductive adhesive.  
     
     
         87 . The process of  claim 86  wherein said-step of imparting electrically conductive areas on said layer of non-conductive adhesive is accomplished by cutting openings in said conductive adhesive and filling said openings with an electrically conductive material.  
     
     
         88 . The process of  claim 87  wherein said step of filing openings is accomplished with a gravure roller.  
     
     
         89 . The product of the process of  claim 87 .  
     
     
         90 . The process of  claim 84  further comprising the step of applying a vacuum during the step of heating and pressing said aligned solar cell gore, said substrate gore and said adhesive.  
     
     
         91 . The process of  claim 90  wherein said vacuum is about 8 to 45 Torr.  
     
     
         92 . The product of the process of  claim 89 .  
     
     
         93 . The process of  claim 84  wherein said substrate gore layer is gas pervious.  
     
     
         94 . The process of  claim 93  wherein said substrate gore layer is a fabric layer.  
     
     
         95 . The product of the process of  claim 94 .  
     
     
         96 . The process of  claim 93  wherein said fabric layer includes electrically conductive warp threads.  
     
     
         97 . The product of the process of  claim 96 .  
     
     
         98 . The process of  claim 84  wherein said step of introducing a conductive conduit is achieved by utilizing a fabric having electrically conductive warp threads.  
     
     
         99 . The product of the process of  claim 98 .  
     
     
         100 . A process for making an energy producing stratospheric airship comprising: 
 (a) depositing flexible solar cells on an airship gore polymer film to produce a solar cell gore layer;    (b) aligning said solar cell gore layer with a substrate gore layer;    (c) adding a non-conductive adhesive layer between said solar cell gore layer and said substrate gore layer;    (d) bonding said solar cell gore layer to said substrate gore layer under heat and pressure to provide an energy producing airship gore; and    (e) joining said energy producing airship gore with additional gores to form an airship.    
     
     
         101 . The product of the process of  claim 100 .  
     
     
         102 . The process of claim 100 wherein said substrate gore layer is a gas pervious fabric.  
     
     
         103 . The process of  claim 102  wherein said gas pervious fabric has a set of electrically conductive warp threads.  
     
     
         104 . The product of the process of  claim 103 .  
     
     
         105 . The process of  claim 103  wherein said gas pervious fabric has a second set of electrically conductive warp threads separated from said first set of electrically conductive warp threads by electrically non-conductive weft threads.  
     
     
         106 . The product of the process of  claim 105 .  
     
     
         107 . The process of  claim 103  further comprising the step of introducing a conductive conduit intermediate said solar cell gore layer and said substrate gore layer.  
     
     
         108 . The product of the process of  claim 107 .  
     
     
         109 . The process of  claim 100  wherein said step of bonding is accomplished under a vacuum.  
     
     
         110 . The process of  claim 109  further comprising the step of introducing a conductive conduit intermediate said solar cell gore layer and said substrate gore layer.  
     
     
         111 . The process of  claim 110  further comprising the step of introducing a second conductive conduit intermediate said solar cell gore layer and said substrate gore layer.  
     
     
         112 . The product of the process of claim  111 .