CN101075646A - 被动冷却型太阳能聚光光电装置 - Google Patents

被动冷却型太阳能聚光光电装置 Download PDF

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CN101075646A
CN101075646A CN200710101752.7A CN200710101752A CN101075646A CN 101075646 A CN101075646 A CN 101075646A CN 200710101752 A CN200710101752 A CN 200710101752A CN 101075646 A CN101075646 A CN 101075646A
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optical element
radiator
photoelectric cell
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photovoltaic device
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CN100544036C (zh
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戴维·K·福克
斯蒂芬·J·霍恩
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(xerox Company) Palo Alto Research Center Inc
Solfocus Inc
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    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/052Cooling means directly associated or integrated with the PV cell, e.g. integrated Peltier elements for active cooling or heat sinks directly associated with the PV cells
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
    • H01L31/04Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof adapted as photovoltaic [PV] conversion devices
    • H01L31/054Optical elements directly associated or integrated with the PV cell, e.g. light-reflecting means or light-concentrating means
    • H01L31/0547Optical elements directly associated or integrated with the PV cell, e.g. light-reflecting means or light-concentrating means comprising light concentrating means of the reflecting type, e.g. parabolic mirrors, concentrators using total internal reflection
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y02E10/50Photovoltaic [PV] energy
    • Y02E10/52PV systems with concentrators

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Abstract

一种卡塞格仑型聚光太阳能收集电池,包括设置在透光(如玻璃)光学元件的凸面和凹面上的主镜和二级镜。光进入围绕二级镜的孔径表面,并被主镜反射射向二级镜,该二级镜再次反射该光到光电电池。光电电池安装到覆盖主镜延伸的散热器的中心部。散热器以在光学元件上均匀分布热量的方式从光电电池传递废热,从而将热量最大限度地从孔径表面辐射到空间中。该散热器包括形成在柔性衬底(如聚酰亚胺薄膜)上的厚的铜层,该柔性衬底被设置成便于安装到光学元件的凸面上的径向臂的样式。

Description

被动冷却型太阳能聚光光电装置
技术领域
本发明涉及太阳能发电机,尤其涉及在固态电介质太阳能聚光光电(CPV)装置的光电(PV)电池中及其附近所产生的热量的处理。
背景技术
用于产生电能的光电太阳能收集装置大体上包括平面收集器和聚光收集器。平面收集器大体上包括光电电池阵列和形成在半导体(例如,单晶硅或多晶硅)衬底上的相关的电子器件,而从平面收集器输出的电能直接与阵列的面积相关,因而需要大的、昂贵的半导体衬底。聚光收集器通过使用例如聚集光线的抛物线反射镜或透镜聚集光线(即,太阳光),产生直接照射到小光电电池上的强度更大的太阳能束,从而降低了对大半导体衬底的需求。因而,聚光收集器具有优于平面收集器的优势在于,它们使用数量少得多的半导体。聚光收集器优于平面收集器的另一个优势在于,它们在产生电能的效率更高。
传统聚光太阳能收集器的一个问题在于,其操作和维护的成本非常高。传统收集器所使用的用于聚集光线的反射镜和/或透镜是单独制造的,并且必须小心地组装,以使所会聚的光线和光电电池正确地对齐。此外,随着时间的过去,反射镜和/或透镜会由于热循环或震动而不再对准,并会由于暴露到外界而变脏。以清洗和调整反射镜/透镜为形式的维护非常重要,尤其当反射镜/透镜具有难于清洗的不平坦的形状时。
传统聚光太阳能收集器的另一个问题在于会聚光线所产生的过高的温度导致光电电池和镜体结构的损坏。为了可靠地工作,必须使光电电池和其周围的包装处于安全范围内,典型的安全范围为低于100摄氏度(100℃)。由于平板光电模块受到太阳光(即未聚焦的)直射,在零风状态(zero wind)下,大部分平板光电模块在最好的隔离条件下的温升为高于环境温度约25℃。这样光电电池的最高温度约为70℃(即,假设环境温度为45℃)。相比之下,聚光太阳能收集器在PV电池上产生300至1000日光以上的辐射流密度,典型地少于一半的能量被转化成电能,其余的以热量的形式出现,这个热量使得光电电池的温度可以达到大大高于100℃。传统的降低聚光太阳能收集器中的光电电池温度的方法包括利用加压液体(forced liquid)冷却系统来冷却该光电电池,但是这种加压液体冷却系统的制造和维护的成本很高,从而大幅度地增加了这种聚光太阳能收集器的整体制造和维护成本。
需要一种聚光光电(CPV)装置,该装置相比于传统的聚光型光电电池,组装和维护成本较低,并同时以成本效率高且可靠的方式将聚光光电装置维持在可靠的工作温度下。
发明内容
本发明涉及卡塞格仑型(Cassegrain-type)聚光光电装置,该装置通过利用散热器将居中设置的PV电池发出的热量均匀分布到固体光学元件的背表面,并利用固体光学元件将该散热器发出的热量传导到前面的孔径表面,热量从该前孔径表面散出,从而有效地从收集器的前面散发热量。这种装置有利于所产生的热量的超过30%从前孔径表面辐射出,从而与从后表面辐射热量的中空收集器系统相比,被动冷却性能提高了约两倍。此外,固体光学元件有利于在其上直接形成主镜和二级镜,从而自动且永久地对准聚光光学器件,并在最小化维护成本的同时保持最佳的光学操作。
根据本发明的一方面,散热器的侧向热阻小于固体光学元件的截面热阻,从而通过使热量分布最大化而优化辐射热传导,以使光学元件保持大致一致的温度,并由此使孔径表面保持大致一致的温度。在一个实施例中,固体光学元件包括厚度在5mm至12mm范围内且直径约为28mm的低铁玻璃结构,而散热器包括名义厚度约为70微米的铜散热层。在这个厚度下,铜散热层热阻的侧向热阻远远大于光学元件的截面热阻,从而产生所需的均衡的加热和从前孔径表面的辐射。
根据本发明的一个实施例,散热器包括形成于柔性衬底(例如,聚酰亚胺薄膜,如DuPont Electronics所生产的Kapton)上的热传导层(例如,铜),光电电池在装配到固体光学元件前被安装在散热器上,从而大幅低地简化了组装过程。在一个实施例中,柔性衬底被切割或以其他方式分割成多个从中心支撑区延伸的径向臂,该径向臂有利于在组装时与固体光学元件的曲面的下表面紧密接触。选择性地使用散热器的配线层,以帮助将热量传向光学元件。在一个实施例中,主镜包括薄的银反射层、设置在银层上的铜防迁移层以及设置在该防迁移层上的阻挡漆层。然后,散热器通过适当的粘合剂(如乙烯-醋酸乙烯共聚物(EVA))被固定到该阻挡漆层上,一防护壳(例如Tedlar)利用相同的粘合剂固定到该柔性衬底的背面。
附图说明
本发明的这些和其它的特征、方面和优点,将通过随后的说明书、所附权利要求、和附图而变得更加清楚,其中:
图1为根据本发明一实施例的聚光光电装置的立体分解图;
图2为图1中的聚光光电装置工作时的剖面侧视图;
图3为根据本发明的另一实施例的聚光光电装置的立体分解图;
图4为图3中的聚光光电装置的详细的剖面侧视图;
图5为图3的聚光光电装置中使用的散热器衬底的立体图;以及
图6为图3中的聚光光电装置的组装后的立体图。
具体实施方式
本发明涉及处理固体电介质太阳能聚集器中的光电电池及其周围所产生的热量,如在共有且共同未决的美国专利申请中所公开的,该美国专利申请的序列号为11/110,611,题目为“CONCENTRATING SOLAR COLLECTORWITH SOLID OPTICAL ELEMENT”,这里引入其全部内容作为参考。具体地,本发明涉及被动热量处理系统,该系统通过使30%以上的产生出的热量从固体光学元件的前孔径表面辐射而避免了导热的液体冷却系统的生产和维护成本。
考虑到聚光光电装置的辐射平衡,必须了解天空的黑体温度典型地为-40摄氏度(-40℃)左右。地面的黑体温度典型地为高于环境温度约4℃。从而需要为装置的前表面提供一热通道,这样就可以向空中辐射热量。
在数量上,聚集器的前表面的每单元面积的净辐射通量可以表示为:
Q f = ϵ f σ T f 4 - ( 1 - R f ) σT s 4 方程1
其中,εf为前表面的发射率(对低铁玻璃,典型值为0.85),σ为斯忒藩玻耳兹曼(Stefan-Boltzmann)常数(5.67×10-8Watts/m2Kelvin4),Tf为前表面的绝对温度,Rf为前表面的反射率(典型地约为8%),以及Ts为天空的黑体温度(约-40℃)。
从聚集器的背面射出的辐射可以类似地表示为:
Q b = ϵ b σ T b 4 - ( 1 - R b ) σT g 4 方程2
其中,εb为背表面的发射率(对塑料层压Tedlar,典型地为0.9),Tb为聚集器的背表面的绝对温度,Rb为聚集器的背表面的反射率(在红外线中,对于Tedlar,典型地约为10%),以及Tg为地面或屋顶的黑体温度(典型地为高出环境温度约4摄氏度)。
由方程1和方程2可以明显看出,与背面相比,前表面向温度低的多的路径辐射。在平面光电系统中,典型地,从面板前面散失的热量比从后面散失的热量多两倍。本发明的有用方面为制造一种模仿这个有利的散热机制的聚光型PV系统。
图1为根据本发明的一简化实施例的内镜的卡塞格仑型(Cassegrain-type)聚光光电(CPV)装置的分解立体图。聚光太阳能收集器100一般包括光学元件110、光电(PV)电池120、主镜130、二级镜140以及散热器150。
光学元件110为固体、盘状、透光的结构,包括:上层111;从上层111的下侧突出的相对较大的凸面112;设置在上层111上侧的基本平坦的孔径表面115;以及,限制在孔径表面115中(即,延伸到上层111内)的相对较小的凹(弯曲)面(凹陷)117。为了最小化材料、重量、厚度和光吸收,上层111可以是非常小的。在一个实施例中,光学元件110利用低铁玻璃(例如,英国Pilkington PLC生产的Optiwhite玻璃)结构,采用已知的玻璃成型方法塑成的。可选地,可以加工并抛光透明塑料来形成单片的光学元件110,或者可以粘合或以其他方式固定多个分离的片来形成光学元件110。在优选实施例中,光学元件110为5mm至12mm厚,且20mm至40mm宽。这个厚度有助于保证从而背面的凸面112到孔径表面115的热传导路径不会像更厚或者中空的光学元件那样具有过大的热阻。
光电电池120位于限定在凸面112中心的中心第一侧(凹腔)区113。举例来说,光电电池120通过合适的导线122和124(如图2所示)利用已知技术连接到相邻的聚光光电装置(未示出)的PV电池。举例来说,由Spectrolab,Inc.of Sylmar,California,USA生产的合适的光电(聚光太阳能)电池。
主镜130和二级镜140分别设置在凸面112和凹面117上。如图2所示,主镜130和二级镜140被设置成,使得沿通过孔径表面115的特定区域进入到光学元件110的预定方向(例如,垂直于孔径表面115)传播的光束LB,被主镜130的相应区域反射到二级镜140的相关区域,并从二级镜140的相关区域反射到光电电池120(例如,直接从二级镜140反射到光电电池120,或通过位于二级镜和光电电池120之间的反射面或折射面反射到光电电池120)。这里所示用的方向术语如“上”、“下”、“上方”和“下方”,仅用于为说明提供相对的位置,而不用于指定参考的绝对结构。在一个实施例中,主镜130和二级镜140通过在凸面112和凹面117上溅射或以其他方式沉积反射性镜面材料(例如银(Ag)或铝(Al))而制成,从而使得制造成本最小化并提供优良的光学特性。利用已知的镜面制造技术,通过溅射或其它方式在凸面112和凹面117上形成镜面膜,主镜130大致为凸面112的形状,二级镜140大致为凹面117的形状。这样,模塑或采用其它的方式制造光学元件110,使得凸面112和凹面117被设置并成形为所需的镜面形状。注意,通过形成具有所需的镜面形状和位置的凸面112和凹面117,主镜130和二级镜140可以有效地自形成并自对准,从而消除了伴随传统聚光太阳能收集器的高昂的组装和校准成本。此外,由于主镜130和二级镜140保持粘贴在光学元件110上,它们的相对位置被永久性地设定,从而消除了对传统多部件装置中可能需要的调整和重心校准的需求。在一个实施例中,主镜130和二级镜140利用同一的(相同的)一种或多种材料(如电镀银)同时形成,从而使制造成本最小化。此外,通过利用光学元件110的表面制造镜面,一旦光通过孔径表面115进入到光学元件110中,光线在到达光电电池120之前,仅被主镜130/凸面112和二级镜140/凹面117反射。这样,光线仅仅经过一个空气/玻璃分界面(即,孔径表面115),从而最小化传统的多部件聚光太阳能收集器中所出现的损失。单一的空气/玻璃分界面损失可以通过在孔径表面115上设置一防反射涂层而进一步降低。虽然也可以单独形成主镜130和二级镜140,然后将镜面分别贴在凸面112和凹面117上,然而这种生产方法会大幅度增加制造成本,并会降低将镜面薄膜直接形成在凸面112和凹面117上所带来的优良的光学特性。
散热器150包括中心部151和从该中心部151向外延伸的曲面的外围部152。散热器150包括一种具有相对高的热传导系数的材料,并包括一厚度,选择该厚度使得散热器150的侧向热阻TR1(即,从中心部151到外围部152的外边缘沿径向测量得到的)小于光学元件110的截面热阻TR2(即,从凸面112到孔径表面115测量得到的)。在一实际的例子中,多个小的聚光光电装置100排列在一起,以防止玻璃的体积变得过大,并在不进行主动冷却的条件下保持每个光电电池的能量的量可控。在优选实施例中,使用厚度介于5mm至12mm的低铁玻璃制造光学元件110,而散热器150包括一厚度为70微米的铜质热分散层(即,两盎司铜),该铜质热分散层的热阻TR1大于光学元件110的热阻TR2。在这个厚度下,铜制热分散层的侧向热阻大于光学元件的截面热阻。
如图2所示,散热器150的中心部151被设置为覆盖凹腔113,弯曲的外围部152形成在或者以其它方式固定在主镜130的背面(非反射面)。光电电池120被安装在中心部151的内表面上,使得光电电池120被设置在凹腔113中。如硅树脂(例如,聚二苯基联苯硅氧烷或聚甲基苯基硅氧烷)的填充间隙的透明粘合剂128也设置在凹腔113中覆盖光电电池120,用于使得凹腔113和光电电池120之间的折射率的破坏性突变最小。注意,在主镜130中限定中心开口131,以利于光通过开口131射到光电电池120上。在一个实施例中,光电电池通过散热块(heat slug)127安装在中心区域151上。在另一个实施例中,在中心区域151和散热块127上形成有一个或多个开口,以利于从光电电池120导出电流,例如,通过导线122和124导出。在另一个实施例中,电流以与共有且共同待决的美国专利申请序列号11/110,611(上文引用)中公开的相似的方式,通过散热器150或主镜130从光电电池120中导入或者导出。
虽然主镜130和散热器150在图1和图2中作为单独的层来示出,在一个实施例中,可以在凸面112上形成单一的层,用于实现主镜130和散热器150的功能。也就是说,镜面典型地通过薄的500埃的Ag层和一个或多个防护层形成,该防护层可以包括薄的1000埃的Cu防迁移层和/或阻挡漆层。这种传统的镜面具有一相对较高侧向热阻,但还不足以充分地分散光电电池120的热量使光学元件110实现均衡的热分布。因此,覆盖镜面的背面形成有具有高的热传导率的材料(如铜)的相对较厚的层,以提供所需的热分布。当需要这两个单独的层不仅提供最佳反射表面并且提供足够的热传导时,可以使用单一的(例如,银或铜)层来同时实现反射和热传导功能。尽管如此,目前形成促进充分热传导所需厚度的银在经济上是不可行的,而使用已知技术沉积铜被认为只能形成无法满足要求的镜面。
图2为工作中的聚光太阳能收集器100的侧视图。与传统的聚光太阳能收集器类似,收集器定位系统(图中未示出,例如,在Amonix,Incorporated ofTorrance,California,U.S.A生产的MegaModuleTM系统中所使用的跟踪系统)被用于定位聚光太阳能收集器100,使得光束LB(如太阳光线)以所需的方向(如垂直于孔径表面115)直接进入孔径表面115。光电电池120大致设置在会聚区F中,该聚光区F指光束LB被主镜130、二级镜140和任何中间光学结构(例如,电通量聚集器)会聚的区域。为了便于在中心区域113中定位会聚区F,凸面112、主镜130、凹面117和二级镜140在光轴X上对中并大致绕光轴X对称设置(即,凸面112和凹面117的曲面部分由一绕光轴X旋转的弧所限定),其中,该光轴X沿大致垂直于孔径表面15的方向延伸。
根据本发明,如图2中的虚线箭头CH1所示,在焦点F上产生的废热(即,由没有被光电电池120转化成电能的太阳能所产生的热量),经由中心部151(当有散热块127时,经过该散热块127)通过传导热传递被传递到外围部152。对本发明来说,术语焦点用于既指由成像元件会聚也指由非成像元件会聚。如图2中的虚线箭头CH2所示,以这种方式传向外围部152的热量通过主镜130和凸面112被传到光学元件110中,并通过传导性热传递被传到孔径表面115。如波状虚线箭头RH所示,热量从孔径表面115被辐射到空间中。
图3为根据本发明的另一实施例的聚光光电装置200的立体分解示意图。与聚光太阳能收集器100相似,聚光太阳能收集器200包括光学元件210、光电电池220、形成在光学元件210的凸面212上的主镜230、形成在光学元件的凹面217上的二级镜240、以及散热器250。
如图3所示,光学元件210包括绕孔径表面215的外围边缘设置的六个相互邻接的面219。如在共有且共同待决的美国专利申请序列号11/110,611(上述引用)中所详细论述的,这种六面结构有利于以高空间利用率的方式形成聚光太阳能收集器200的大型阵列。在其它的实施例中,可以利用具有其它外围形状(如前面所述的聚集器100的圆形外围形状)的聚集器生产空间利用率较低的聚光太阳能收集器阵列。在凸面212中限定(例如,模塑成)中心区(凹腔)213,用于容纳光电电池220。
图4为简化的、局部的分解剖视图,具体示出了聚光光电装置200的各个部件。
在一个实施例中,用于制造聚光光电装置200的生产工艺从在光学元件210上形成主镜230和二级镜240开始。首先,高反射性(镜面)材料层232和242(如银)分别被沉积在凸面212和凹面217上。可以通过各种技术涂覆银,包括建筑用途常用的在玻璃生产镜子的液态镀银技术。银也可以通过已知的如直流磁控溅射的溅射技术来涂覆。
接下来,防迁移层234和244(例如,铜)分别被沉积在高反射材料层232和242上。在浸液或喷雾技术中,这个过程典型地使用化学镀Cu工艺(electroless Cu process)。在溅射工艺中,如钛或铬镍铁合金(inconel)的金属被用于覆盖并保护银不锈蚀。接下来,可选的阻挡漆层236和246分别形成在防迁移层234和244上。典型地,通过喷涂工艺涂覆阻挡漆并在随后烘烤以使阻挡漆变干变硬。
接下来,内部粘合层260(如Dupont生产的EVA(乙烯-醋酸乙烯共聚物)粘合剂)被沉积在阻挡层236上,而透明粘合剂228被沉积到凹腔213中。举例来说,凹腔213可以在进行层压工艺之前用未硬化的粘合剂填充。在涂覆内部粘合层260时应当非常小心,以确保其不进入到孔213中。在另一实施例中,粘合层260被粘附在散热器250上,而不是光学元件210上。粘合层260的公称厚度约为100微米。关于聚光光电装置200的各层的层压的其它细节在共有且共同待决的美国专利申请中公开,该专利申请的序列号为11/382,008,题目为“LAMINATED SOLAR CONCENTRATING PHOTOVOLTAIC DEVICE”[代理编号为No.20060351-US-NP(XCP-071)]中公开,该专利申请与本申请的优先权申请一起提交并在此引入其全部内容作为参考。
制造散热器250,并在将其安装到粘合层260之前,与光电电池220组装。根据本发明的另一方面,散热器250为包括形成在柔性衬底250A(例如,聚酰亚胺膜,如DuPont Electronics生产的Kapton,0.5mm厚)上的一层或多层传导层250B(例如铜或其它金属)的多层衬底(工业上称为“柔板(flex)”)。可以使用3M公司(美国明尼苏达州圣保罗)的Kapton柔板制造散热器250。如图5所示,散热器(柔板)250由平坦的薄片通过切割或其它方式构成图案而制成,使其包括中心部251和从该中心部251沿径向延伸并被切口254分隔开的多个外围部252(径向臂)。光电电池220典型地具有顶部(受光侧)电插头和底部电插头。安装在散热器250上并与之保持机械接触和电接触的光电电池220,其顶部电插头可以与散热块电连接,该散热块又与柔板的一个导电部电连接。底部电插头与柔板的第二导电部电连接。在热传导层250B中包括多个电通道的一个实施例中,光电电池220的基极和发射极均与热传导层250B电连接。在能量单元阵列中,传导层250B的一部分可用于通过并联或串联从光电电池220将电流导出。光电电池220和热传导层250B之间可以直接连接,也可以通过中层封装或散热块连接。在另一实施例中,铜传导层可以由热膨胀系数与光学元件210的更匹配但不是很好的导电体或导热体的金属或合金(如合金42(Fe-Ni合金))替代。进一步的改进为利用粘结的层叠金属,例如铜和合金42,来形成散热器。这种结构与铜相比具有优良的热膨胀特性,且不会降低电导率。
根据本发明的另一方面,散热器250通过粘合层260共形地贴附到主镜230上,使得热传导层250B与光学元件210实现良好的机械接触和热接触。通常,如图5所示,柔板以张或卷的形式处理,所以其本身是平的。通过将散热器250的外围部252A和252B做成图5所示的图案,当散热器250被安装到内部粘合层260上时,柔性衬底250A和热传导层250B与弯曲的凸面212相适应,如图3和图6所示,从而有利于对散热器250造型,以在热传导层250B和光学元件210之间提供紧密地热接触。可以在外围部252上打通孔,以有利于粘合层260和275之间的结合。
在可选的实施例中,可以使用既能实现热传递又能实现导电功能的冲压金属片料作为散热器250。当多聚光光电装置阵列并联时,可以制作包括散热块、散热器和接线的并具有在阵列外部系在一起的发射极和基极导线的冲压件或成形件,从而在层压之后可以将其整理并分开。光电电池可以滑入到三明治结构中,该三明治结构以经过一个焊接回流(solder reflow)步骤来进行两面接触的结构从电池前面套入并与背面相接触。但是,这种设置的作用类似于闸刀(guillotine),当施加压力时可能会破坏电池。一可选的实施例中,利用单独的冲压金属件或成形金属件来形成在聚集器内部的散热块、散热器和电池阵列并联接线的一边。并联接线的另一边可以被设置为例如一块柔板。关于热嵌片的使用和其它的封装特性在共有且共同待决的美国专利申请中公开,该美国专利申请序列号为11/382,004,题目为“SOLAR CONCENTRATINGPHOTOVOLTAIC DEVICE WITH RESILIENT CELL PACKAGE ASSEMBLY”[代理编号为No.20060466-US-NP(XCP-070)],该申请与本申请的优先权申请一起提交并在此引入其全部内容作为参考。
在另一可选的实施例中,一双面散热器装置在Kapton衬底的两侧均设有铜。这会使结构变得更加复杂,但会消除Kapton/EVA分界面。
之后,使用外部(例如,EVA)粘合层275将一塑料防护壳层270(例如,DuPont生产的厚度为150微米的Tedlar)固定到柔性衬底250A的暴露表面。由于Kapton为惰性材料,需要进行表面处理以适于粘附到EVA。例如,可以在组装前通过对Kapton表面进行等离子体处理或对Kapton使用硅烷偶联剂来进行表面处理。在一个实施例中,在将层叠的部件组装到一起以进行层压之前,可以在该表面处理之后直接在柔性衬底上涂覆一层EVA。
聚光光电装置200的柔性导体(例如,铜)沿侧向的热阻与光学元件玻璃沿垂直方向的热阻是可比的,而聚光光电装置200利用了这个发现。其结果是,本发明的聚集器具有5mm至12mm厚的玻璃和70微米厚的铜层,该结构的两个零件都不会成为从孔径表面215热传递的严重瓶颈。充足的散热确保了在聚光光电装置200的前面和背面的大面积上产生辐射冷却和对流冷却。这使得光电电池的表面温度更加均匀且结温(junction temperature)更低。正常工作条件下的聚光光电装置200的热模型,在环境温度为300°K,电池转换效率为35%的条件下,其结温比环境温度高不到30℃。尽管本装置将太阳光会聚几百倍而且仅使用被动冷却,电池的结温仅比传统的不聚光的平板模式的太阳光收集器高出了环境温度约5℃。对这里所述的发明,在正常工作条件下,热流计算预计67%或约三分之二的热流穿过上表面流出聚集器。
虽然参照特定的具体实施例描述了本发明,然而本领域的普通技术人员应当清楚,本发明的发明特征还可以应用到其它实施例中,所有这些都落入本发明的范围中。举例来说,可以先形成主镜和二级镜,然后利用合适的粘接剂将其安装到光学元件上,但这种尝试会大幅度地增加生产成本。在另一可选实施例中,用于形成二级镜的曲面可以是凸面而不是凹面,从而形成经典的格利高里型系统(Gregorian type system)。在另一可选实施例中,用于形成主镜和二级镜的曲面可以是椭圆形的、椭球形的、球形的、和其他的曲面形状。

Claims (10)

1、一种聚光光电装置,包括:
固体的透光的光学元件,其包括相对的第一表面和第二表面,并限定了一焦点,该光学元件所接收的光被会聚到该焦点;
散热器,包括覆盖该光学元件的焦点设置的中心部,以及一个或多个从该中心部在改第一表面上延伸的外围部;以及
光电电池,设置在散热器的中心部上。
2、根据权利要求1所述的聚光光电装置,其特征在于,
所述散热器具有从该中心部向该外围部延伸的侧向热阻;
所述光学元件具有从该第一表面向该第二表面延伸的截面热阻;以及
所述截面热阻大于所述侧向热阻。
3、根据权利要求1所述的聚光光电装置,其特征在于,所述散热器包括一个或者多个金属镀层,而所述光电电池与所述一个或者多个金属镀层电连接。
4、根据权利要求1所述的聚光光电装置,其特征在于,
所述光学元件包括相对较大的凸面,该凸面限定了中心第一侧区,以及相对的孔径表面和相对较小的曲面,该相对较小的曲面位于该孔径表面的中心部;
所述中心第一侧区包括一凹腔;以及
该光电电池设置在该凹腔孔中在散热器的中心部和光学元件的邻近表面的之间。
5、根据权利要求4所述的聚光光电装置,其特征在于,进一步包括设置在凹腔中的在该光电电池和所述光学元件的邻近表面之间的透明粘合剂。
6、根据权利要求4所述的聚光光电装置,其特征在于,进一步包括:设置在所述凸面和所述散热器的外围部之间的主镜,以及设置在所述曲面上的二级镜,其中,设置所述主镜和二级镜使得通过孔径表面进入到光学元件的光线会聚到该中心第一侧区,从而该会聚的光在所述中心第一侧区产生热量。
7、根据权利要求6所述的聚光光电装置,其特征在于,所述主镜和所述二级镜包括分别直接形成在所述凸面和所述凹面上的反射镜膜。
8、一种制造聚光光电装置的方法,包括:
形成一固体的透光的光学元件,该光学元件具有限定了中心第一侧区的相对较大的凸面、以及相对的孔径表面和被限定在该孔径表面的中心部的相对较小的曲面;
形成一散热器,所述散热器包括覆盖光学元件的中心第一侧区而设置的中心部,以及从该中心部延伸的外围部;以及
将散热器安装到光学元件上,使得外围部共形地设置在该凸面上。
9、根据权利要求8所述的方法,其特征在于,进一步包括:
将光电电池安装到散热器的中心部,
其中,将散热器安装到光学元件包括在中心第一侧区内设置光电电池。
10、根据权利要求8所述的方法,其特征在于,进一步包括:在将散热器安装到光学元件之前,将外围部分割为多个径向指状物。
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