Manhattan 2

R&D Initiative To Create Low-Carbon Society

Mass Produce Smart Solar Material That Includes Switches/Processor

Factory Production Line Makes Smart Solar Material

Every building in the world should be completely covered with solar photovoltaic material, from roof-edge to roof-edge. MA2 engineers must develop a continuous factory process that manufactures solar material that includes solar cells, conductors, switches, processors, and diagnostics.

Smart Solar Lamination

Layers consist of solar cells, conductors, internal printed circuit boards, switches, processors, and metal backing for strength and fire protection. The blue layer is a solar cell that converts sun light to electricity. Total thickness is 1 to 4mm (0.04 to 0.16"). Material is later placed directly onto plywood roofs or onto corrugated steel panels.

Complex Conductor Pattern

In the above 1x4meter illustration we show one layer for aluminum conductors in the X direction (gray), one layer for conductors in the Y direction (blue), and a control/switching PCB (red).

1m x 2m Solar Cell Array

Solar cells produce different voltages (e.g. 76V, 38V, 19V, 10V, etc.) that route to internal PCB; as shown in 1x2meter concept.

Smart Solar Produces Sinewaves

Switches on PCB produce AC and DC voltages at different voltage levels and frequencies, as required by the various components (e.g. ideal power into compressor motor might be 35Hz at 82VAC). The PCB does much of the DC to AC conversion while relying on external filter components for cleanup.

Factory does not make the same pattern over and over again. Instead it is under computer control to assemble material as needed. Some layers can be thought of as continuous “roll-to-roll”, yet others are inserts in-between those layers.

Metal stamping machines create patterns in aluminum at low cost.

Mount Conductors onto Sheet of Plastic

Stamping machine creates conductors and attaches to sheet of plastic: (1) Conductors (shown in red) are pressed into the mold (green), (2) upper stem (pink) keeps conductors in mold while press (gold) retracts, (3) plastic sheet (orange) with adhesive is placed above mold, and (4) lower stem (violet) presses conductors against plastic.

Connect Multiple Layers With Spot Weld

Stamping machine punches holes in aluminum and insulation to make room for internal components and spot welded tabs that connect two aluminum layers to build electrical circuit.

Design & Build Prototype Production Line

MA2 engineers design and build multiple prototype production lines that fabricate smart solar material. MA2 engineers create sample material and accurately calculate cost. MA2 funds prototype production lines at universities interested in automated solar (e.g. CMU, GIT, UICU, UCB, UMA, MIT).

Solar Mass Production

Henry Ford revolutionized transportation with mass production. We need to do the same with solar. This has not been done previously due to a lack of standards that define how components interconnect. MA2 needs to create these in order to propel solar forward. The solar industry needs to think more like Henry Ford and less like Rolls Royce.