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APPENDICES!

Confidential!Material! ! Sugico!Mök!
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William!Mook,!CEO!!
Mök!Industries!

Advances!1996!through!2006!

Confidential!Material! ! Sugico!Mök!
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Low"cost!Photovoltaic!Panel!Design!&!Construction!
!

This! is! a! new! sort! of! concentrating!

photovoltaic!system!that!consists!of!arrays!
of!lenses!similar!to!that!shown!here.!!There!
is! a! fish"eye! type! wide! angle! refractive!
imaging! lens! up! top,! a! non"imaging!
conical!reflector!in!the!middle,!and!a!non"
imaging!compound!parabolic!concentrator!
down! below.! ! In! the! exit! plane,! is! a! small!
photovoltaic!cell!soldered!onto!conductive!
copper!foil,!embedded!in!a!plastic!lattice.!!!

The! lens! system! consists! of! thin! film! clear!

plastic,!such!as!PET,!(the!same!material!as!
soda! bottles)! filled! with! ultra"pure! clear!
water.! ! Since! the! water’s! refractive! index!
matches! the! refractive! index! of! the! plastic!
used,!any!irregularity!in!the!PET!surface!is!
invisible.! ! This! is! why! water! bottles! filled!
with! water! appear! to! be! far! clearer! than!
! water!bottles!that!are!empty.!!!

The! plastic! film! holds! the! water! in! a! lens"

like! shape,! and! the! water! itself! is! the! lens!
medium.!!This!way!the!film!can!be!molded!
into!lens!shapes!at!far!lower!cost!than!with!
an!all!plastic!lens.!!Also,!only!a!very!small!
amount! of! plastic! is! used! for! a! given! lens!
volume.! ! ! Large! volume! lenses! can! be!
made! less! precisely! than! small! volume!
lenses!of!the!same!capacity!which!reduces!
manufacturing!costs.!

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The!film!is!hot"press!molded!in!four!layers.!!The!bottom"most!layer!has!copper!foil!imbedded!in!
it.!!Photo!voltaic!cells!are!then!soldered!onto!the!foil.!!Another!layer!is!thermally!joined!to!the!
bottom!layer!to!create!a!sparse!array!of!photo"voltaic!cells.!!The!top!two!layers!are!formed!and!
joined!to!the!completed!bottom!layer!immersed!in!a!water!bath.!!A!lens!array!of!artibtrary!size!
may!be!formed.!

The! concentrating! ! photovoltaic! system!

described! here! consists! of! panels! each! 8!
feet! by! 4! feet! in! area! comprised! of! 4,196!
lenses.! ! Each! lens! has! one! square! inch!
area.!!Each!lens!illuminates!a!photovoltaic!
cell! one! square! millimeter! in! area.! ! So,! in!
each!8!foot!by!4!foot!panel!there!are!4,196!
photovoltaic! cells! each! one! square!
millimeter! in! area.! ! This! means! that! a!
typical! 300! mm! diameter! wafer,! costing!
$140! for! first! run! commercial! crystalline!
silicon,! with! typical! yields,! can! make! 14! panels! each! 8! feet! by! 4! feet! in! area.! ! So,! the! cost! of!
photovoltaic!materials!is!only!$10!per!panel.!!These!same!wafers!if!used!to!make!a!conventional!
panel!would!cost!$11,820!from!the!same!wafers.!!The!power!produced!under!illumination!is!the!
same!in!either!case.!!

The! plastic! film! which! contains!

the! water! costs! $4.48! per! 8! foot!
by!4!foot!panel.!!The!water!costs!
$0.30!per!ton,!and!the!water!cost!
is!nil!per!panel.!!The!copper!foil,!
copper! wire,! and! structural!
stainless! steel! cable! adds! the!
most! cost,! nearly! $23.00! per!
panel.! ! Overall,! the! cost! per!
panel! is! less! than! ! $38.00! each.!!!!!
Each! panel! produces! 580! watts!
under! full! illumination.! ! This! is!
6.54!cents!per!peak!watt.!!!

Confidential!Material! ! Sugico!Mök!
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Panels! may! be! produced! individually,! and!

individually! placed! and! wired.! ! But! the!
lowest! cost! method! of! installation! involves!
pre"wiring!as!many!panels!at!the!factory!as!
can! be! conveniently! handled.! ! Think! of!
Christmas!tree!light!strings.!!Our!panels!are!
built!the!same!way.!

One!thousand!one!hundred!8!foot!by!4!foot!
panels! can! be! wired! together! into! 110!
separate! circuits,! presenting! 55! separate!
circuits!at!either!end!of!the!string.!!The!1,100!
panels! are! z"folded! onto! a! 53! foot! flat"bed!
trailer,!to!form!a!shipping!volume!of!12!feet!
by! 8! feet! by! 53! feet,! and! conveniently!
shipped! anywhere.! ! Thus,! a! single! tractor"
trailer! combination! can! ship! 0.638! MW! of!
solar!panels.!!!

Installing! the! panels! involves! pulling! the!

string!with!a!special!tractor!from!East!to!West!after!staking!one!end!of!the!string!to!the!ground.!!
Panels!then!unzip!from!their!z"fold!arrangement,!and!the!special!tractor!equipped!with!disks,!
‘plant’!the!panels!in!an!8!foot!wide!strip!that!is!nearly!1!mile!long.!!!

Electrical!connections!are!made!at!either!
end,! to! variable! load! electrolyzers,! or!
variable!load!sodium"sulfur!batteries.!!It!
is!estimated!a!crew!of!eight!working!one!
shift! with! four! tractors! can! install! 520!
strings! covering! nearly! one! square! mile!
of!surface!area!every!week.!!!

Confidential!Material! ! Sugico!Mök!
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Industrial! Design! Construction! Company’s!

Pittsburgh!office,!a!division!of!CH2M!HILL!LTD!
worked! closely! with! me! detailing! every!
manufacturing! step! involved! in! creating! a! plant!
that! would! be! most! economical.! ! The! design!
shown! above! is! for! a! specific! site! in! New! Castle!
PA,! at! a! place! called! Millenium! Park.! ! This! $1.6!
billion!facility!has!the!ability!to!produce!1!square!
mile!of!solar!panels!at!a!cost!of!less!than!$0.07!per!
peak!watt!installed!every!2.8!days.!!The!plant!can!
produce! 71! GW! of! panels! each! year.! ! It! employs!
690! people! full"time.! ! An! associated! silicon!
foundry! is! also! planned! for! the! site! and! will!
employ! an! additional! 820! people.! ! This! silicon!
foundry!is!typical!of!this!type!of!facility.!

The!land!needed!to!operate!hundreds!of!
square! miles! of! panels! is! obtained! from!
large! surface! mine! operators! who!
operate! surface! mines! in! sunny! regions.!!
Anglo! Ashanti! Gold! and! Newmont!
Mining! both! operate! lands! leased! from!
Union! Pacific! Railroad! in! Northern!
Nevada.!!These!lands!have!a!total!area!in!
excess! of! 4,400! square! miles! in! this!
region.!!This!is!an!area!greater!than!all!the!rooftops!of!all!the!buildings!in!the!continental!United!
States.!!Due!to!recent!‘brightfield’!legislation!enacted!in!the!past!year,!bonding!companies!have!
expressed!an!interest!in!guaranteeing!the!reclamation!of!land!that!we!cover!with!our!low"cost!
solar!panels!for!a!premium!that!is!a!fraction!of!the!current!reclamation!cost!for!these!companies,!
saving!these!companies!billions!of!dollars.!!Once!I!have!a!credible!scale!of!production!to!cover!
this! acreage! it! is! very! well! possible! that! I! could! receive! amounts! in! excess! of! the! cost! of! the!
proposed!factory!described!above!to!sign!leases!that!take!over!this!land!and!use!them!for!solar!
collector!sites.!

Confidential!Material! ! Sugico!Mök!
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BREAKTHROUGH!TECHNOLOGY!

At! the! Earth’s! surface! direct! sunlight! posseses! 850! Watts! per! square! meter.!! That’s! 850! micro"
watts!per!square!millimeter.!!Converted!at!15%!efficiency!to!electricity!by!silicon!PV!cells!!this!
represents! a! power! of! 127.5! microwatts! electrical! per! square! millimeter.! At! a! cost! of! $1.00! per!
square!inch!for!silicon!a!square!millimeter!costs!100/645.16!=!0.15!cents!per!sqare!mm.!!In!terms!
of!power!this!is!a!penny!for!every!850!microwatts.!!This!is!$11.76!per!watt.!!Which!is!10x!greater!
than!the!cost!of!conventional!generators.!

!However,! by! concentrating! sunlight! 100x! to! 500x! using! mirrors! or! lenses,the! energy! density!
may!be!raised!by!the!same!factor!as!the!concentration,!reducing!costs!by!the!same!factor.!!So,we!
can!see!that!its!possible!by!using!low"cost!concentrators!costs!per!watt!can!be!reduced!to!a!range!
of!$0.12!and!as!low!as!$0.02!per!watt!!

!The! trouble! with! increasing! the! power! levels! is! the! existence! of! parasitic! losses! in! the! PV!
device.!!The!parasitic!losses!arise!from!i"squared!R!heating!as!the!current!increases.!!This!loss!!
mechanism!grows!as!the!square!of!intensity!while!the!output!grows!linearly.!Therefore,we!have!
a! situation! where! diminishing! returns! occur,! and! peak! output! is! achieved! with! any! further!
increase!in!intensity!resulting!in!lowered!output.!

!The!form!of!the!equation!is;!

!!!!!!!!!!!!!Pout!=!Vout!*!Rload!–!!I^2!*!Rinternal!

!Where!I!is!the!current.!!

!Since!I!is!proportional!to!intensity!(i)!we!can!rewrite!the!equation;!

!!!!!!!!!!!!!Pout!=!A!*!(!Vout!*!Rload!–!i^2!Rinternal)!

!Typical!photocells!achieve!peak!intensity!of!2!to!4!x!ambient!solar!output.!!!

!There!are!two!ways!to!reduce!parasitic!losses.!!

!!

(1)!!!!!Reduce!Rinternal!and!

(2)!!!!!Increase!Vout!(thus!reducing!I)!

Confidential!Material! ! Sugico!Mök!
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!!

The! reducing! Rinternal! was! first! done! by!

Swanson! through! using! back"junction!
photocells.! Increasing! Vout! was! first!
achieved! by! Sater! through! his! vertical!
multi"junction!cell!technology.!

!By! increasing! the! number! of! junctions!

40x!the!voltage!of!the!PV!device!increases!
by!40x.!This!reduces!the!impact!of!I^2!by!a!
factor!of!40x40!=!1,600x!

!Swanson! has! achieved! reductions! of!

Rinternal! by! a! factor! of! 100! –! thus!
increasing! peak! intensity! by! a! factor! of!
100.!!!

!The! object! of! the! following! design! is! to!

combine! both! improvements! into! a!
completely! new! innovation! and!
essentially!eliminating!parasitic!losses.!

!1.5! mm! x! 1.5! mm! =! 2.25! sq! mm.!! 5”!

wafers! =! 12,667! sq! mm,! implies! 5,630!
dies.!! With! a! 50%! yield,this! is! 2,500!
dies! per! wafer.!! 5! to! 10! wafers! yield!
12,500!to!25,000!dies.!!

!Each! die! operating! at! 150x! solar!

intensity!produces!43!milliwatts.!!Each!
wafer!produces!therefore!107.5!watts.!!
At!450x!this!triples!to!over!322.5!watts!
per! wafer.! !At! $20! to! $30! per! wafer!
this! translates! to! $0.10! and! $0.20! per!
watt.!!!Doubling!yield!would!improve!
pricing!to!$0.05!to!$0.10!per!watt.!!Our!
ultimate! target! for! PV! costs! is! $0.03!
per!watt!at!500x!intensity.!

Confidential!Material! ! Sugico!Mök!
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EVOLUTION!OF!PROTOTYPE!TECHNOLOGY!

An! important! aspect! in! creating! low"cost! solar! energy! is! the! ability! to! collect! sunlight! at! a!
reasonable! price! and! concentrate! it! to! high! intensity.! ! Mök! has! achieved! this! in! a! number! of!
ways.! ! At! first! we! used! spun! aluminum! parabolas! coated! with! mylar! to! focus! sunlight.! ! This!
proved! our! core! technology.! ! Next,! we! used! aluminized! PET! formed! into! fresnel! mirrors! as!
shown.!!Finally,!we!hit!upon!making!low!cost!lens!arrays!from!PET!to!create!stationary!lenses!
that!need!not!track!the!sun.!!This!final!innovation!has!allowed!Mök!to!build!solar!collectors!for!
less!than!three!cents!per!peak!watt.!!This!allows!Mök!to!create!energy!for!1/5th!cent!per!kilo"watt!
hour.!

PENNSYLVANIA!PRODUCTION!PLANT!AND!CENTRAL!COLLECTOR!LAYOUT!

This! 1.2! million! square! foot! facility! will! employ! 690! people! directly.! ! It! will! produce! a! square!
mile!of!solar!collectors!every!2.8!days.!!These!!4’!x!8’!x!2”!collector!panels!will!be!strung!together!
in!strings!of!1,100!forming!a!string!1!mile!wide.!!The!string!will!be!‘z’!folded!onto!a!52’!truck!for!
shipment!anywhere!in!the!US.!!The!strings!will!be!unfolded!and!planted!by!a!special!planting!
tractor.!!Five!tractors!and!crew!will!install!the!output!of!the!plant.!!The!strings!will!charge!utility!
scale! batteries.! ! These! batteries! will! drive! HVDC! power! lines! to! distribute! DC! power! to!
wherever!its!needed.!

Confidential!Material! ! Sugico!Mök!
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BERGIUS!PROCESS!!!

During! World! War! Two! Germany! made! great! use! of! synthetic! fuel! –! this! was! based! on! its!
extensive! deposits! of! bituminous! and! brown! coal.! ! High! quality! syntheteic! fuel! was!
manufactured! mainly! by! two! processes:! Bergius! Hydrogenation! (developed! in! 1926)! and!
Fischer"Tropsch!(developed!in!1923).!!

The! Bergius! process! involved! splitting! the! complex! molecules! of! coal! and! then! forcing!
hydrogen!into!them!under!high!pressure!to!produce!liquid!oil!molecules.!In!the!Fischer"Tropsch!
process,! molecules! of! hydrogen! and! carbon! monoxide,! obtained! by! breaking! up! coal! with!
steam,!were!used!to!form!oil!molecules.!

The!Bergius!hydrogenation!was!superior!to!Fischer"Tropsch.!!By!1944!Germany!was!producing!
about! 47%! of! all! it’s! oil! products! including! nearly! 100%! of! its! aviation! fuel! using! Bergius!
hydrogenation! for! this! reason.! ! The! high! cost! of! hydrogen! today! is! the! only! reason! Bergius!
hydrogenation!is!not!in!wide!use.!!Mök’s!low!cost!solar!hydrogen!changes!this!condition.!

The! Mök! Process! uses! renewable! hydrogen! derived! from! sunlight! and! water! to! power! a!
modified!Bergius!Process!resulting!in!six!barrels!of!oil!from!each!ton!of!coal!while!producing!no!
emissions.!

Confidential!Material! ! Sugico!Mök!
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