CN102013443B - 供在聚光式太阳能系统中使用的太阳能电池接收器子组合件 - Google Patents

供在聚光式太阳能系统中使用的太阳能电池接收器子组合件 Download PDF

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CN102013443B
CN102013443B CN201010269175.4A CN201010269175A CN102013443B CN 102013443 B CN102013443 B CN 102013443B CN 201010269175 A CN201010269175 A CN 201010269175A CN 102013443 B CN102013443 B CN 102013443B
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约翰·纳吉瓦里
彼得·艾伦·扎瓦兹基
史蒂夫·西尔
詹姆斯·福雷西
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Abstract

一种供在聚光太阳能系统中使用的太阳能电池接收器子组合件,其以1000或1000以上的倍数将太阳能聚光到太阳能电池上以用于将太阳能转换成电,所述太阳能电池接收器子组合件包含:光学元件,其界定光学通道;太阳能电池接收器,其具有:支撑件;太阳能电池,其安装于所述支撑件上而邻近于所述光学元件且位于所述光学通道的光学路径中,所述太阳能电池包括一个或一个以上III-V族化合物半导体层且能够产生超过20瓦的峰值DC电力;二极管,其安装于所述支撑件上且与所述太阳能电池并联耦合;及第一和第二电触点,其安装于所述支撑件上且与所述太阳能电池及所述二极管并联耦合;及囊封物,其覆盖所述支撑件、所述太阳能电池、所述二极管及所述光学元件的外部侧的至少一部分。

Description

供在聚光式太阳能系统中使用的太阳能电池接收器子组合件
技术领域
本申请案针对一种供在聚光器光伏系统中使用的太阳能电池子组合件,更特定来说,针对一种包含太阳能电池、经金属化陶瓷衬底及聚光器光学元件的经囊封太阳能电池接收器。
背景技术
历史上,太阳能电力(在太空与陆地两者中)一直主要由硅太阳能电池提供。然而,在过去的几年中,对用于太空应用的高效III-V族化合物半导体多结太阳能电池的大量制造已使得人们能够考虑到将此替代技术用于陆地电力产生。与硅相比,III-V族化合物半导体多结电池通常更能抵抗辐射且具有更大的能量转换效率,但其制造起来往往花费更多。一些当前III-V族化合物半导体多结电池具有超过27%的能量效率,而硅技术通常仅达到约17%的效率。在聚光条件下,一些当前III-V族化合物半导体多结电池具有超过37%的能量效率。
一般来说,所述多结电池具有p上n极性且由InGaP/(In)GaAs/Ge半导体结构的垂直堆叠组成。III-V族化合物半导体多结太阳能电池层通常经由金属有机化学气相沉积(MOCVD)生长在锗(Ge)衬底上。使用Ge衬底准许在n型与p型Ge之间形成结,借此利用所述衬底来形成底部或低带隙子电池。太阳能电池结构通常生长在平均质量密度为约86mg/cm2的100-mm直径Ge晶片上。在一些工艺中,在MOCVD生长过程期间跨越容纳12或13个Ge衬底的底板的外延层均匀度优于99.5%。随后可通过以下步骤将外延晶片处理成成品太阳能电池装置:自动化机器人光刻、金属化、化学清洗及蚀刻、抗反射(AR)涂覆、切割以及测试过程。n触点及p触点金属化物通常主要由Ag构成,其具有薄Au封盖层以保护Ag免遭氧化。AR涂层是双层TiOx/Al2O3电介质堆叠,其光谱反射率特性经设计以最小化盖玻璃互连电池(CIC)或太阳能电池组合件(SCA)层面处的反射,以及最大化电池的寿命终止(EOL)性能。
在一些化合物半导体多结电池中,与GaAs电池不同,中间电池是InGaAs电池。对于InGaAs中间电池,铟浓度可在约1.5%的范围中。在一些实施方案中,这一布置展示出增加的效率。使用InGaAs层的优点是,此类层可与Ge衬底大致更好地晶格匹配。
发明内容
根据一实施例,一种用于将太阳能转换成电的太阳能电池子组合件包含:光学元件,其界定光学通道;太阳能电池接收器,其包括:
支撑件;太阳能电池,其安装于所述支撑件上而邻近于所述光学元件且位于所述光学通道的光学路径中,所述太阳能电池包括一个或一个以上III-V族化合物半导体层且能够产生超过20瓦的峰值DC电力;及囊封物,其覆盖所述支撑件、所述太阳能电池及所述光学元件的外部侧的至少一部分。
在另一方面中,本发明提供一种制造太阳能电池接收器的方法,其包括:提供支撑件;在所述支撑件上安装太阳能电池,所述太阳能电池包括一个或一个以上III-V族化合物半导体层且能够产生超过20瓦的峰值DC电力;在所述太阳能电池上方安装界定光学通道的光学元件,使得将所述太阳能电池安置于所述光学通道的光学路径中;及囊封所述支撑件、所述太阳能电池及所述光学元件的外部侧的至少一部分。
本发明并不限于以上特征及优点。在阅读以下具体实施方式且观看附图后,所属领域的技术人员将认识到额外特征及优点。
附图说明
图1是包含太阳能电池、经金属化陶瓷衬底及散热器的太阳能电池接收器的实施例的部分分解透视图。
图2更详细地显示图1的太阳能电池及经金属化陶瓷衬底。
图3是图1中所示的太阳能电池、经金属化陶瓷衬底及散热器的横截面图。
图4是图3中所示的太阳能电池、经金属化陶瓷衬底及散热器在附接聚光器光学元件及囊封物之后的横截面图。
具体实施方式
现在将描述本发明的细节,包含其实例性方面及实施例。参照图式及下文描述,相同的参考编号用于识别相同或功能上类似的元件,且打算以高度简化的图示方式图解说明实例性实施例的主要特征。此外,所述图式既不打算描绘实际实施例的每一特征,也不打算描绘所描绘元件的相对尺寸,且这些图式并非按比例绘制。
太阳能电池接收器包含用于将太阳能转换成电的太阳能电池。在本文所描述的各种实施方案中,采用了三结III-V族化合物半导体太阳能电池,但可使用其它类型的太阳能电池,这取决于应用。太阳能电池接收器通常含有额外组件,例如,用于耦合到输出装置或其它太阳能电池接收器的连接器。
对于一些应用,太阳能电池接收器可实施为太阳能电池模块的一部分。太阳能电池模块可包含太阳能电池接收器及耦合到所述太阳能电池接收器的透镜。所述透镜用于将所接收的光聚焦到太阳能电池接收器上。由于透镜,所述太阳能电池接收器可接收到对太阳能的更大聚光。在一些实施方案中,所述透镜适于以400或400以上的倍数聚光太阳能。举例来说,在500个太阳聚光下,1cm2的太阳能电池面积产生与在无聚光的情形下500cm2的太阳能电池面积将产生的相同的电力量。因此,聚光的使用允许用例如透镜及镜的高成本效益材料来替代较为昂贵的半导体电池材料。可将两个或两个以上太阳能电池模块一起组合成一阵列。这些阵列有时称为“板”或“太阳能板”。
图1图解说明包含太阳能电池102的太阳能电池接收器100的实施例。在一个实施例中,太阳能电池102是三结III-V族化合物半导体太阳能电池,其包括串联布置的顶部电池、中间电池及底部电池。在另一实施例中,太阳能电池102是具有p上n极性的多结太阳能电池且由Ge衬底上的InGaP/(In)GaAsIII-V族化合物构成。在每一情况下,太阳能电池102经定位以从辅助光学元件104接收所聚焦的太阳能。
辅助光学元件104定位于太阳能电池102与例如透镜的主要聚焦元件(未显示)之间。辅助光学元件104通常经设计以朝向太阳能电池102的上表面收集由对应透镜聚光的太阳能。辅助光学元件104包含从对应透镜接收光束的进入孔口105及将所述光束传输到太阳能电池102的出射孔口107。辅助光学元件104包含位于孔口105、107之间的中间区域112。在理想条件下,与辅助光学元件104相关联的透镜将光直接聚焦到太阳能电池102而不使光碰到辅助光学元件104上。
在大多数情形中,所述透镜不将光直接聚焦于太阳能电池102上。此可由于各种原因而发生,包含但不限于折射透镜设计的色差、构造期间太阳能电池102相对于透镜的不对准、操作期间由于跟踪器误差、结构性挠曲及风力负载所致的不对准。因此,在大多数条件下,所述透镜聚焦光使得所述光反射离开辅助光学元件104。理想设置与不对准设置之间的差异可以是透镜定位中小于1°的较小变化。
因此,辅助光学元件104充当光溢散捕捉器以在对应透镜不将光直接聚焦于太阳能电池102上时的情形中致使所述光中的更多光到达太阳能电池102。辅助光学元件104可包含反射多层中间区域,例如2009年3月12日提出申请的序列号为12/402,814的美国专利申请案(其内容以全文引用的方式并入本文中)中所揭示的种类。所述反射多层中间区域可由不同材料形成且具有不同光学特性,使得离开辅助光学元件104且被传输到太阳能电池102的光束的反射率优化太阳能电池102的表面上的聚合辐照度而胜过入射太阳能光谱。举例来说,在一些实施方案中,可用银或另一材料涂覆辅助光学元件104的本体112的内表面以实现高反射率。在一些情况下,反射涂层由例如SiO2的钝化涂层保护以保护辅助光学元件104免遭氧化、锈蚀或腐蚀。
辅助光学元件104的本体112具有一个或一个以上安装凸耳114,其用于经由一个或一个以上紧固件118将本体112附接到托架116。提供托架116以用于经由一个或一个以上紧固件122将辅助光学元件104安装到散热器120。托架116为导热性,使得在操作期间由辅助光学元件104产生的热能可转移到散热器120并耗散。如此实施方案中所显示,辅助光学元件104具有四个反射壁。在其它实施方案中,可采用不同的形状(例如,形成三角形横截面的三侧形状)。辅助光学元件104可由金属、塑料或玻璃或其它材料制成。
在图2中所示的一个实施例中,聚光器106安置于辅助光学元件104的出射孔口107与太阳能电池102之间。聚光器106优选地为玻璃且具有光学入口108及光学出口110。在一个实施例中,聚光器106为实心玻璃。聚光器106增强从辅助光学元件104出射的光且朝向太阳能电池102引导经增强的光。在一些实施方案中,聚光器106具有从入口108到出口110呈锥形的大体正方形横截面。在一些实施方案中,聚光器106的光学入口108是正方形且为约2cm×2cm,而光学出口110为约0.9cm×0.9cm。聚光器106的尺寸可随太阳能电池模块及接收器的设计而变化。举例来说,在一些实施方案中,光学出口110的尺寸与太阳能电池102的尺寸大约相同。在一个实施例中,聚光器106为2X聚光器。聚光器106的底表面可使用粘合剂(例如硅酮粘合剂)直接附接到太阳能电池102的上表面。太阳能电池102通过光伏效应将传入太阳光直接转换成电。
旁路二极管124与太阳能电池102并联连接。在一些实施方案中,二极管124是一种例如肖特基(Schottky)旁路二极管或外延生长p-n结的半导体装置。出于图解说明的目的,旁路二极管124为肖特基旁路二极管。提供外部连接端子125及127以用于将太阳能电池102及二极管124连接到其它装置,例如邻近太阳能电池接收器(未显示)。
通过考虑串联连接的多个太阳能电池102可了解旁路二极管124的功能性。可将每一太阳能电池102设想为一蓄电池,其中二极管124中的每一者的阴极连接到相关联“蓄电池”的正端子且二极管124中的每一者的阳极连接到相关联“蓄电池”的负端子。当串联连接的太阳能电池接收器100中的一者受到损坏或遮蔽时,其电压输出减少或消除(例如,到低于与二极管124相关联的阈值电压)。因此,相关联二极管124受到正向偏压,且旁路电流仅流过所述二极管124(而不流过太阳能电池102)。以此方式,未受损或未受遮蔽的太阳能电池接收器100继续从那些太阳能电池所接收的太阳能中产生电。如果不是因为旁路二极管124,那么其它太阳能电池接收器所产生的大致所有电都将通过受遮蔽或受损的太阳能电池接收器,从而将其毁坏,并在(例如)所述板或阵列内形成开路。太阳能电池接收器100还包含用于安装太阳能电池102的陶瓷衬底126(例如氧化铝衬底)及用于耗散在操作期间由太阳能电池102产生的热的散热器120。
图2更详细地图解说明太阳能电池102及陶瓷衬底126。陶瓷衬底126具有经金属化上表面及下表面128及130。陶瓷衬底126的两个表面128及130经金属化以增加陶瓷衬底126的热转移能力,从而使太阳能电池接收器100能够更充分地处置由于太阳能电池操作条件的突然改变而发生的快速温度改变。举例来说,太阳能电池102在将光转换成电时产生热能。使陶瓷衬底126的上表面及下表面128及130两者均金属化实现将热能从太阳能电池102较快地转移到散热器120以供耗散。当太阳能电池102突然被遮掩时,发生相反状况。也就是说,太阳能电池102停止产生电并与辅助光学元件104一样快速冷却。陶瓷衬底126的经金属化上表面及下表面128及130通过将热能从散热器120转移到太阳能电池102(且取决于热状况还转移到辅助光学元件104)来防止太阳能电池102过快地冷却。太阳能电池接收器100的增加的热转移能力减少了在快速温度改变期间赋予太阳能电池102与陶瓷衬底126之间的界面的应力量,从而确保可靠的太阳能电池到衬底界面。
陶瓷衬底126的经金属化上表面128与太阳能电池102接触且具有分离的传导区域132及134以用于提供到太阳能电池102的隔离的导电路径。第一传导区域132提供太阳能电池102的阳极电接触点且第二传导区域134提供太阳能电池102的阴极电接触点。太阳能电池102具有在图2中看不到但在图3的横截面中可看见的传导下表面136,所述传导下表面定位于陶瓷衬底126的经金属化上表面128的第一传导区域132上且连接到所述第一传导区域。太阳能电池102的相对上表面138具有传导接触区140,所述传导接触区连接到陶瓷衬底126的第二传导区域134。
在一个实施例中,太阳能电池102的传导下表面136形成太阳能电池102的阳极端子,且安置于太阳能电池102的上表面138处的传导接触区140形成阴极端子。根据此实施例,太阳能电池102的传导下表面136定位于陶瓷衬底126的第一传导区域132上且与第二传导区域134电隔离以确保太阳能电池102的正确操作。在一个实施例中,陶瓷衬底126的第一传导区域132在三个侧上由陶瓷衬底126的外围区域周围的第二传导区域134至少部分地环绕。
在一个实施例中,安置于太阳能电池102的上表面138处的传导接触区140占据太阳能电池102的周长。在一些实施方案中,上部传导接触区140可以是更小或更大以适应所需连接类型。举例来说,上部传导接触区140可仅触及太阳能电池102的一个、两个或三个侧(或其若干部分)。在一些实施方案中,上部传导接触区140制作得尽可能小以最大化将太阳能转换成电的面积且同时仍允许电连接。尽管太阳能电池102的特定尺寸将视应用而变化,但标准尺寸为约1cm2。举例来说,一组标准尺寸可为总体约12.58mm×12.58mm、约0.160mm厚且总有效面积为约108mm2。举例来说,在大约12.58mm×12.58mm的太阳能电池102中,上部传导接触区140可为约0.98mm宽且有效面积可为约10mm×10mm。
太阳能电池102的上部传导接触区140可由各种传导材料(例如,铜、银及/或涂覆有金的银)形成。在此实施方案中,正是太阳能电池102的n-传导阴极(即,发射极)侧接收光,且因此上部传导接触区140安置于太阳能电池102的阴极侧上。在一个实施例中,太阳能电池102的上部传导接触区140经由一个或一个以上接合线142而线接合到陶瓷衬底126的经金属化上表面128的第二传导区域134。
旁路二极管将陶瓷衬底126的经金属化上表面128的第一传导区域132耦合到第二传导区域134。在一个实施例中,旁路二极管124的阴极端子经由陶瓷衬底126的第一传导区域132连接到太阳能电池102的阳极端子,且旁路二极管124的阳极端子经由陶瓷衬底126的第二传导区域134电连接到太阳能电池102的阴极端子。太阳能电池102的阳极端子如上文所描述的那样由太阳能电池102的下部传导表面136形成,且在图2中看不到但在图3的横截面中可看见。太阳能电池102的阴极端子也如上文所描述的那样由太阳能电池102的上部传导接触区140形成。安置于陶瓷衬底126的经金属化上表面128上的外部连接端子125及127实现装置到太阳能电池102及旁路二极管124的电耦合。在一些实施方案中,连接器端子125及127对应于阳极及阴极端子,且经设计以接纳用于连接到邻近太阳能电池接收器的插座插头(未显示)。
可通过将金属化层132及134附接到陶瓷衬底126来金属化所述衬底的上表面128。在一个实施例中,在金属化层132、134中形成孔144。图2显示陶瓷衬底126具有附接到上部衬底表面128(下部经金属化表面在图2中看不到,但在图3的横截面中可看见)的两个金属化层132及134。通过高温反应性接合或其它类型的接合过程将金属化层132及134附接到陶瓷衬底126的上表面128。可以类似方式金属化陶瓷衬底126的下表面130并将其附接到散热器120。
图3图解说明太阳能电池接收器100的太阳能电池102、陶瓷衬底126及散热器120的沿图1中标示为X-X’的线的横截面图。为便于图解说明,未在图3中显示辅助光学元件104、聚光器106及端子125、127。陶瓷衬底126的上表面及下表面128及130经金属化。衬底126的上部经金属化表面128具有分离的传导区域132及134以用于提供到太阳能电池102的电隔离的阳极及阴极连接,如上文所描述。
太阳能电池102具有连接到陶瓷衬底126的经金属化上表面128的传导区域132的传导下表面136。在一个实施例中,太阳能电池102的传导下表面136形成太阳能电池102的阳极端子,且安置于太阳能电池102的上表面138处的传导接触区140形成太阳能电池102的阴极端子。太阳能电池102的传导下表面136定位于陶瓷衬底126的经金属化上表面128的第一传导区域132上且与第二传导区域134电隔离以确保太阳能电池102的正确操作。
陶瓷衬底126的下表面130还具有金属化层148,所述金属化层借助高导热附接介质150(例如填充有金属的环氧树脂粘合剂或焊料)接合到散热器120。用金属填充环氧树脂粘合剂增加陶瓷衬底126与散热器120之间的界面的导热性,从而进一步改进太阳能电池接收器100的热转移特性。在一个实施例中,高导热附接介质150是填充有金属的环氧树脂粘合剂,其具有大约1到3密耳的厚度tepoxy。可将填充有金属的环氧树脂粘合剂施加到陶瓷衬底126的下部经金属化表面130、散热器120或两者且接着将其固化以将散热器120接合到衬底126。在一个实施例中,散热器120是单片式挤制铝散热器,如图1中所示。
可通过以下步骤制造太阳能电池接收器100:提供经金属化陶瓷衬底126;及将太阳能电池102的传导下表面136连接到衬底126的经金属化上表面128的第一传导区域132。(例如)经由一个或一个以上接合线142将安置于太阳能电池102的上表面138处的传导接触区140连接到陶瓷衬底126的经金属化上表面128的第二传导区域134。借助填充有金属的环氧树脂粘合剂150将散热器120接合到陶瓷衬底126的下部经金属化表面130。
图4图解说明太阳能电池接收器100的太阳能电池102、陶瓷衬底126及散热器120在借助适合透光粘合剂151将聚光器106接合到太阳能电池102的上表面138之后的沿图1中标示为X-X’的线的横截面图。在聚光器106的附接之后,太阳能电池102由囊封物152环绕,所述囊封物的一个实施例可以是基于硅酮的。将所述囊封物施加在陶瓷衬底126的整个部分上方以环绕太阳能电池102,包含散热器120与陶瓷衬底126的经金属化下表面130之间的区域上方,以及任选地施加在二极管124上方,且接着随后通过热或其它适合过程来固化所述囊封物。

Claims (10)

1.一种供在聚光太阳能系统中使用的太阳能电池接收器子组合件,其以1000或1000以上的倍数将太阳能聚光到太阳能电池上以用于将太阳能转换成电,所述太阳能电池接收器子组合件包括:
太阳能电池接收器,其包括:支撑件,其界定了面向上部方向的上表面及面向下部方向的经金属化的下表面,所述下部方向与所述上部方向相反;
太阳能电池,其界定了面向所述上部方向的上表面及面向所述下部方向的下表面,所述太阳能电池的所述下表面安装于所述支撑件的所述上表面上,其中所述太阳能电池包括一个或多个III-V族化合物半导体层;
辅助光学元件,其界定从光学入口到光学出口的光学通道,且经配置将光朝所述太阳能电池引导,其中所述辅助光学元件界定在光学入口到光学出口之间延伸的至少一个外部侧表面,其中所述光学出口耦合到所述太阳能电池的所述上表面;
囊封物,其覆盖所述支撑件、所述太阳能电池及所述辅助光学元件的所述至少一个外部表面侧的至少一部分,以环绕和封装所述太阳能电池和所述支撑件;
托架,其位于所述辅助光学元件的下方,且为导热性元件,所述辅助光学元件经由一个或多个紧固件附接到所述托架;及
散热器,其位于所述托架的下方,所述托架经由一个或多个紧固件安装至所述散热器。
2.根据权利要求1所述的太阳能电池接收器子组合件,其中所述囊封物为固化的基于硅酮的材料,其直接施加到所述支撑件、所述太阳能电池和所述辅助光学元件的所述至少一个外部侧表面的至少一部分的每一者上,以环绕和封装所述太阳能电池和所述支撑件。
3.根据权利要求1所述的太阳能电池接收器子组合件,其进一步包括安装于所述支撑件的所述上表面上且具有阳极端子及阴极端子的二极管,
其中所述太阳能电池的所述下表面是传导性的,且形成所述太阳能电池的阳极端子,该阳极端子电耦合到所述二极管的所述阴极端子;并且,所述太阳能电池的所述上表面是传导性的,且形成所述太阳能电池的阴极端子,该阴极端子电耦合到所述二极管的所述阳极端子。
4.根据权利要求3所述的太阳能电池接收器子组合件,其进一步包括覆盖所述二极管的囊封物。
5.根据权利要求3所述的太阳能电池接收器子组合件,其进一步包括安装于所述支撑件的所述上表面上的第一和第二电触点,其中所述第一电触点将所述太阳能电池的阳极端子电耦合到所述二极管的所述阳极端子,且所述第二电触点将所述太阳能电池的阴极端子电耦合到所述二极管的所述阴极端子。
6.根据权利要求1所述的太阳能电池接收器子组合件,其中所述太阳能电池的所述上表面具有约1cm×约1cm的尺寸。
7.根据权利要求1所述的太阳能电池接收器子组合件,其进一步包括安置于所述辅助光学元件的所述光学出口与所述太阳能电池的所述上表面之间的透明粘合剂。
8.根据权利要求1所述的太阳能电池接收器子组合件,其中所述辅助光学元件为放大元件。
9.根据权利要求1所述的太阳能电池接收器子组合件,其中所述太阳能电池为三结太阳能电池。
10.根据权利要求1所述的太阳能电池接收器子组合件,其中所述支撑件为具有第一及第二相对的经金属化表面的陶瓷衬底。
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US20110048535A1 (en) 2011-03-03
US9806215B2 (en) 2017-10-31
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