Potted domed solar panel capsule and traffic warning lamps incorporating same

Abstract

A rugged, long lasting, transparent housing of a domed shape protects an embedded solar panel. More particularly, the solar panel is embedded in a polymer in a utilized, potted construction. The use of polyurethane as the polymer produces a durable product which is transparent and resistant to both thermal and mechanical stresses. The domed top over the solar panel improves the solar panel's ability to capture light and thus to operate in locations where the incidence of light is at a low angle as is found in northern latitudes.

1 . A method for encapsulating a solar panel in a fixed mass of transparent protective material comprising the following steps: 
 (a) formation of a solar panel by: 
 (i) covering an assembly of wafers of photovoltaic material, a non-conducting backing sheet, adhesive bonding the wafers to the backing sheet, electrically conductive connections between the wafers and terminal electric conductors attached to the wafers, with a thin layer of liquid polymer material;  
 (ii) curing the liquid polymer material to hardness;  
   (b) encapsulating the solar panel formed in step (a) in an additional mass of transparent protective material by embedding the solar panel formed in step (a) in additional liquid polymer material held in a mold;    (c) embedding the rim of a component housing in the additional liquid polymer; and    (d) curing the additional liquid polymer material until it solidifies.    
     
     
         2 . The method claimed in  claim 1  wherein the curing for the formation of the solar panel is conducted in a vacuum at a temperature of approximately 50 degrees Celsius.  
     
     
         3 . The method claimed in  claim 1  wherein the material selection for the polymer material of steps (a) and (b) is the same.  
     
     
         4 . The method claimed in  claim 1  wherein the polymer material used is a two-component reactive polyurethane.  
     
     
         5 . The method claimed in  claim 1  wherein the mold has a smooth concave shape.  
     
     
         6 . The method claimed in  claim 1  wherein the component housing contains: 
 (a) rechargeable batteries;    (b) one or more lamps;    (c) electronic circuitry to control the operation of the lamps and the charging of the rechargeable batteries; and    (d) electrical connectors connecting the solar panel to the rechargeable batteries, the lamps and the electronic circuitry.    
     
     
         7 . The method claimed in  claim 1  wherein strengthening material, the presence of which increases the strength or rigidity of the solar panel or the component housing to which the solar panel is attached, is embedded in the additional liquid polymer material of step (b) prior to the curing conducted in step (b).  
     
     
         8 . The method claimed in  claim 7  wherein the strengthening material is wire, rods, a lattice or a mesh.  
     
     
         9 . The method claimed in  claim 7  wherein the strengthening material is made of metal.  
     
     
         10 . A solar generator, comprising: 
 (a) wafers of photovoltaic material;    (b) a non-conducting backing sheet;    (c) adhesive bonding the wafers of photovoltaic material to the backing sheet;    (d) electrically conductive connections between the wafers of photovoltaic material;    (e) terminal electric conductors attached to the wafers of photovoltaic material; and    (f) a solid mass of transparent protective material having a generally dome-shaped convex surface and in which the wafers of photovoltaic material, the non-conducting backing sheet, the adhesive, the electrically conductive connections and the terminal electrical conductors are embedded.    
     
     
         11 . The solar generator claimed in  claim 10  wherein the dome-shaped surface of the mass of transparent protective material is without a peripheral rim.  
     
     
         12 . The solar generator claimed in  claim 10  wherein the mass of transparent protective material is a two-component reactive polyurethane.  
     
     
         13 . The solar generator claimed in  claim 10  wherein the solid mass of transparent protective material having a dome-shaped surface has further embedded in it the rim of a component housing.  
     
     
         14 . The solar generator claimed in  claim 13  wherein the component housing contains: 
 (a) rechargeable batteries;    (b) one or more lamps;    (c) electronic circuitry to control the operation of the lamps and the charging of the rechargeable batteries; and    (d) electrical connectors connecting the solar panel to the rechargeable batteries, the lamps and the electronic circuitry.    
     
     
         15 . The solar generator claimed in  claim 10  wherein the solid mass of transparent protective material having a dome-shaped surface has further embedded in it strengthening material the presence of which increases the strength or rigidity of the solar generator.  
     
     
         16 . The solar generator claimed in  claim 15  wherein the strengthening material is wire, rods, a lattice or mesh.  
     
     
         17 . The solar generator claimed in  claim 16  wherein the strengthening material is made of metal.  
     
     
         18 . The solar generator claimed in  claim 10  mounted in the surface of a supporting structure wherein the dome-shaped surface of the mass of transparent protective material is selected to have a curvature that matches smoothly that of the surface in which the solar generator is mounted.  
     
     
         19 . The solar generator claimed in  claim 18  wherein the supporting structure is a traffic control bollard.  
     
     
         20 . A traffic warning lamp assembly of the type including a photovoltaic solar panel array within a protective housing having a transparent light-receiving protective outer layer for directing light onto the solar panel array, an electrical energy storage device such as a cell or battery electrically connected to the solar panel array for storing electrical energy obtained therefrom, at least one lamp electrically connected to and powered by the storage device, and a switch for interrupting and reconnecting the electric current between the lamp and the storage device; 
 comprising    (a) programmable means such as a microcontroller for selectably operating the switch at selectable times or intervals to interrupt or reconnect the lamp from or to the storage device; and    (b) a data coupling device for connecting one or more inputs of the programmable means to an external source of programming commands and/or input data, said data coupling device optionally including or associated with interface software for facilitating entry of data or commands from the external source to the programmable means.    
     
     
         21 . An assembly as defined in  claim 20 , in combination with a portable source of data and/or programming commands that couples with the data coupling device thereby to permit data and/or programming commands to be transmitted from the portable source to the programmable means.  
     
     
         22 . An assembly as defined in  claim 20 , wherein the data coupling device comprises a wireless receiver.  
     
     
         23 . An assembly as defined in  claim 21 , wherein the source is selected from hand-held programmable and/or communication devices such as a Palm Pilot™, RIM Blackberry™, Handspring™, a television remote control unit or the like.  
     
     
         24 . An assembly as defined in  claim 20 , wherein the lamp is an LED lamp.  
     
     
         25 . An assembly as defined in  claim 20 , including a pair of lamps mounted to face generally in the same direction which, when electrically actuated, are powered on and off at a selected wagger frequency and out of phase with one another.  
     
     
         26 . An assembly as defined in  claim 25 , additionally comprising a standard for supporting the lamps above the ground, and serving as a cross-walk indicator.  
     
     
         27 . An assembly as defined in  claim 25 , wherein the lamps, when powered on, flicker at a frequency selected to save energy while attracting visual notice.  
     
     
         28 . A traffic warning lamp assembly of the type having: 
 (a) an exterior protective housing;    (b) a photovoltaic solar panel array;    (c) a solar panel protective housing mounted in a portion of the exterior housing facing ambient light during daylight, said solar panel protective housing enveloping the photovoltaic solar panel array and having a transparent light receiving protective outer layer for directing light onto the solar panel array;    (d) an electrical energy storage device such as a cell or battery electrically connected to the solar panel array for storing electrical energy obtained therefrom;    (e) at least one lamp mounted in the exterior housing and electrically connected to and powered by the storage device; and    (f) a switch for interrupting and reconnecting the electric current between the lamp and the storage device;    wherein    the contours or profile of the transparent light-receiving protective outer layer of the solar panel protective housing generally merge with the contours or profile of the portion of the exterior housing in the vicinity of the transparent light-receiving protective outer layer thereby to afford additional physical protection for the solar panel protective housing and its contents.    
     
     
         29 . An assembly as defined in  claim 28 , incorporated into or functioning as a bollard.  
     
     
         30 . An assembly as defined in  claim 28 , wherein the contours or profile of the transparent light-receiving protective outer layer of the solar panel protective housing and the contours or profile of the portion of the exterior housing in the vicinity of the transparent light-receiving protective outer layer are generally convexly curved to facilitate run-off of debris, rain and the like, the convex curvature of the transparent light-receiving protective outer layer of the solar panel protective housing being selected to facilitate the capture of ambient daylight by the solar panel array.  
     
     
         31 . A protective housing for a solar panel array comprising an integrally formed or bonded housing having a generally convex transparent shock-resistant light-collecting exterior layer interposed, when mounted, between the solar panel array and a source of ambient daylight, characterized by a smooth uninterrupted continuous exterior surface of such exterior layer sealingly isolating the solar panel array from the atmosphere, and free at the periphery thereof from marginal changes of material composition and from abrupt marginal changes of contour.  
     
     
         32 . A protective housing for a solar panel array comprising an integrally formed or bonded housing having a generally convex transparent shock-resistant light-collecting exterior layer interposed, when mounted, between the solar panel array and a source of ambient daylight, characterized in that the protective housing sealingly isolates the solar panel array from the atmosphere, and further characterized by uniformity of material composition throughout the exterior portions of the housing.  
     
     
         33 . A housing as defined in  claim 32 , wherein the solar panel assembly is potted in the protective housing.  
     
     
         34 . A housing as defined in  claim 32 , wherein the protective housing is formed of a selected plastics material, said plastics material being selected for: 
 (a) transparency and refractive capability, to avoid reflecting ambient light away from the solar panel array and to direct a relatively high proportion of light striking the light-collecting exterior layer onto the solar array;    (b) cohesion, sealing capability, ruggedness and shock resistance; and    (c) maintenance of the foregoing qualities over a selected range of expected ambient temperatures and/or in direct sunlight.    
     
     
         35 . A housing as defined in  claim 32 , wherein the selected plastics material is a selected polyurethane.  
     
     
         36 . A method for encapsulating, a solar panel in a fixed mass of transparent protective material comprising the following steps: 
 (a) formation of a solar panel by: 
 (i) covering an assembly of wafers of photovoltaic material, a nonconducting backing sheet, adhesive bonding the wafers to the backing sheet, electrically conductive connections between the wafers and terminal electric conductors attached to the wafers, with a thin layer of liquid polymer material;  
 (ii) curing the liquid polymer material to hardness;  
   (b) encapsulating the solar panel formed in step (a) in an additional mass of transparent protective material by embedding the solar panel formed in step (a) in additional liquid polymer material held in a mold having a smooth concave shape;    (c) embedding the rim of a component housing in the additional liquid polymer; and    (d) curing the additional liquid polymer material until it solidifies.    
     
     
         37 . A method for encapsulating a solar panel in a fixed mass of transparent protective material comprising the following steps: 
 (a) formation of a solar panel by: 
 (i) covering an assembly of wafers of photovoltaic material, a non-conducting backing sheet, adhesive bonding the wafers to the backing sheet, electrically conductive connections between the wafers and terminal electric conductors attached to the wafers, with a thin layer of liquid polymer material;  
 (ii) curing the liquid polymer material to hardness;  
   (b) encapsulating the solar panel formed in step (a) in an additional mass of transparent protective material by embedding the solar panel formed in step (a) in additional liquid polymer material held in a mold, the additional liquid polymer material being of substantially the same composition as in step (a);    (c) embedding the rim of a component housing in the additional liquid polymer; and    (d) curing the additional liquid polymer material until it solidifies.