CN103563092A - 用于聚光器光伏模块的太阳能电池阵列 - Google Patents

用于聚光器光伏模块的太阳能电池阵列 Download PDF

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CN103563092A
CN103563092A CN201280007468.2A CN201280007468A CN103563092A CN 103563092 A CN103563092 A CN 103563092A CN 201280007468 A CN201280007468 A CN 201280007468A CN 103563092 A CN103563092 A CN 103563092A
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E·格斯特
M·齐格勒
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Augustine Canada Electric Co. Ltd.
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Abstract

本发明涉及一种太阳能电池阵列结构，该结构包括：设置在至少一个基板(2)上的多个太阳能电池(4)；设置在该至少一个基板上的多个接触焊盘(5)，多个太阳能电池中的每个太阳能电池对应一个接触焊盘；电布线(8，9)，其将多个太阳能电池中的每个太阳能电池与多个接触焊盘中的对应的一个接触焊盘相连接；以及二极管(7)，其与多个太阳能电池中的至少两个太阳能电池电连接。

Description

用于聚光器光伏模块的太阳能电池阵列
技术领域
本发明涉及用于聚光器光伏模块的太阳能电池阵列，其包含太阳能电池、接触焊盘和至少一个(旁路)二极管。
背景技术
光伏或太阳能电池被设计成用于将太阳辐射转换为电流。在聚光器太阳能光伏应用中，入射的太阳光在引导至太阳能电池之前被光学集中。例如，入射的太阳光被初级反射镜接收，初级反射镜将接收到的辐射朝向次级反射镜反射，接着，次级反射镜再将辐射朝向太阳能电池反射，太阳能电池通过在例如III-V族半导体或单晶硅中产生电子空穴对而将集中的辐射转换成电流。
太阳能电池包括具有金属化的接触焊盘的半导体芯片(semiconductor die)，并因此需要某种方式的集成电路封装或太阳能电池组件，其中，太阳能电池连接到一个或更多个功能器件。太阳能电池组件(SCA)具体地可以提供环境保护、散热以及与太阳能电池的电连接。
在现有技术中，SCA被制备在连续的单个基板基底上或者包括彼此电绝缘的多个组件。关键问题是太阳能电池与SCA的基板的背面接触。通常，充当冷却基板的连续的单一基板通过选择性地沉积贵金属(例如，金)的方法与太阳能电池的背面接触，这意味着冗长并费时的以及昂贵的工艺步骤。
提供若干电绝缘材料元件通常导致差的导热性，并因此导致太阳能电池总的热连接低效。此外，提供不同材料特性的材料意味着更高的费用和多个连接区域，因此导致所制造的SCA的(长寿命)可靠性明显劣化。
此外，在聚光器光伏模块领域中，各个太阳能电池例如通过用于反向过压保护的旁路二极管来独立地布线。当使用二极管作为布线元件时引入相对大的焊盘接触表面并因而引入大的半导体组件。另选地，如果将基于印刷电路板技术的布线焊盘用于太阳能电池的布线，则存在着高风险，即，由于所包括的有机化合物，电路板将被集中的太阳光损坏。
因此，尽管最近的工程学在进展，仍然需要提供这样一种SCA，其表现出可靠的电接触、有效的导热性，还考虑了生产的合理化。
发明内容
本发明解决了以上提及的需要，并相应地提供了一种太阳能电池阵列结构，其包括：
提供在至少一个基板上的多个太阳能电池；
提供在该至少一个基板上的多个接触焊盘，多个太阳能电池中的每个太阳能电池对应一个接触焊盘；
电布线，其将多个太阳能电池中的每个太阳能电池与多个接触焊盘中对应的一个接触焊盘相连接；以及
一个二极管，其与多个太阳能电池中的至少两个太阳能电池电连接，具体地，与连接到多个太阳能电池中的至少两个太阳能电池的接触焊盘的(用于该二极管的)对应的接触焊盘相连接。
具体地，可以将每个太阳能电池提供在各自的可以充当散热器基板的单个的基板(每个太阳能电池对应一个基板)上。每个太阳能电池临近一个设置在其上设置有太阳能电池的同一基板上的接触焊盘。可以将二极管设置在同一基板上，或者设置在与其上设置有太阳能电池与接触焊盘的基板不同的基板上。具体地，接触焊盘可以全部由金属制成。
根据本发明，每个太阳能电池与接触焊盘电连接，并且通过该接触焊盘与保护太阳能电池防止反向过压的二极管电连接。另选地，太阳能电池可以直接接触二极管。因此，根据本发明的布线设计与现有技术相比提供了更多的灵活性。
但是，不同于现有技术，多个太阳能电池例如通过相应的接触焊盘连接到一个并且同一个二极管。因此，不需要给每个单个的太阳能电池提供大的半导体组件，而是仅一个二极管就能够对多个太阳能电池提供过压保护。而且，根据本发明，不将二极管的上表面按如下方式设计，即，允许容纳用于将太阳能电池与相邻的散热物质直接接触的导体和布线。通过接触焊盘来提供太阳能电池和平行的散热物质的必要的电布线，该接触焊盘能够采用与现有技术中的pn半导体二极管相比相对低的费用制成。提供在本发明的太阳能电池阵列结构中的二极管的几何特性仅由所需的电气规范和热规范来确定。
根据一种实施方式，与现有技术中使用的电路板相反，接触焊盘不包括任何绝缘层。根据另一种实施方式，接触焊盘通过电绝缘粘合剂设置在至少一个基板上，该电绝缘粘合剂具体是透明的粘合剂，例如透明的环氧粘合剂，其能避免对入射的集中的太阳光的吸收。另选地，可以通过将粘合剂仅设置在接触焊盘下方的方式来实现，没有被集中的太阳光照射到的风险。
此外，接触焊盘必须适于对太阳能电池与邻近的基板以及二极管的布线，该接触焊盘可以包括由铝、铜、青铜或黄铜制成的基部和/或用于电连接的由金、银、钯、铜、铝、镍、锡或锌制成的表面。
根据一种示例，可以以金属半导体(肖特基)二极管的形式提供与至少两个接触焊盘相连接的二极管。由于太阳能电池的主布线由接触焊盘提供，所以可以选择肖特基二极管而不是如本领域中的大的pn二极管。可以使用电压损失小至0.4V(即，由pn二极管引起的电压损失的大约一半)的肖特基二极管。相比之下，现有技术中使用的pn半导体旁路二极管导致大约0.8V的电压降，且因而导致在旁路情况下整个聚光器光伏模块的电压损失。因此，与现有技术相比可以减少在旁路情况下的电压损失，并且可以增加太阳能电池阵列结构和包括该太阳能电池阵列结构的聚光器模块的总体效率。此外，因为针对肖特基二极管来说热功率损耗低，所以可以减小所需的二极管芯片的尺寸。
如已经提到的，至少一个基板可以充当散热器，因此可以是针对一个或更多个太阳能电池的导热且导电的基板。根据特定的示例，其上设置有太阳能电池的至少一个基板包括铝或铝合金，或由铝或铝合金构成。因此，多个太阳能电池中的每个太阳能电池与多个接触焊盘中的每个接触焊盘可以设置在相应的单一的散热器基板上，并且在散热器基板上的太阳能电池与设置在同一基板上的接触焊盘电连接，且该接触焊盘与可以设置在不同基板上的二极管电连接。
根据本发明的一种实施方式，至少一个基板直接地设置在电绝缘支撑基板(具体地，玻璃支撑基板)上而没有粘合剂。每个都设置有一个或更多个太阳能电池的单个的基板各自与设置在同一基板上的接触焊盘电连接，这些单个的基板可以设置在同一支撑基板上。例如，可以通过热喷涂或等离子涂布处理将铝(散热器)基板施加到支撑基板(例如，由玻璃制成)。由此，铝可以可靠地附着到玻璃表面。喷涂或涂布通常导致喷涂的或涂布的铝层的厚度具有高斯分布。在这种情况下，可以将每个太阳能电池设置在相应的基板(铝层，例如)上的如此形成的基板的最大厚度的区域处，使得由太阳能电池产生的热量可以通过该基板被最佳地扩散。
另选地，至少一个基板是平坦的铝或铝合金板，且通过粘合剂设置在电绝缘的支撑基板上，该电绝缘的支撑基板具体地是玻璃支撑基板或者在上表面包括介电层的金属基板，因此设置有该至少一个基板(例如，平坦的铝板)。取决于基板的尺寸，该至少一个基板可以适用于一个或更多个太阳能电池。如果基板携带多于一个太阳能电池，则需要较少的电连接。
该至少一个基板可以被涂层所涂覆，该涂层提供与太阳能电池和/或二极管的热连接和电连接。该涂层通常比基板本身更薄，并且可以由银、镍、锡、铜或适合作为导电粘合剂或焊料的表面的其它材料或合金中的一种或多种制成；或者包含银、镍、锡、铜或适合作为导电粘合剂或焊料的表面的其它材料或合金中的一种或多种。可以通过导电粘合剂或焊料(具体地，确保可靠的电连接的银粘合剂或焊料)将太阳能电池和/或二极管设置在涂层之上。
另选地，该至少一个基板是平坦的铝板，且通过粘合剂设置在电绝缘的支撑基板上，该电绝缘的支撑基板具体地是玻璃支撑基板或上表面包括介电层的金属基板，因此设置有该至少一个基板(例如，平坦的铝板)。
此外，本文提供了一种聚光器光伏模块，该模块包括根据上文所描述的一种示例的太阳能电池阵列结构。聚光器太阳能电池模块可以包括任何初级聚光器光学装置(例如，本领域中已知的反射镜和菲涅耳(Fresnel)透镜)。聚光器太阳能电池模块还可以包括次级光学器件，例如，圆顶透镜(dome lens)、复合抛物面聚光器(compoundparabolic concentrator)、截顶棱锥(truncated pyramid)或截顶圆锥(truncated cone)。
附图说明
本发明的其它特征和优点将结合附图进行描述。在描述中，参照附图旨在例示本发明的优选实施方式。应当理解的是，这些实施方式并不代表本发明的全部范围。
图1例示了根据本发明的包括二极管和两个太阳能电池阵列的太阳能电池阵列结构的示例。
图2例示了与图1的示例相似但具有不同的布线的包括二极管和两个太阳能电池阵列的太阳能电池阵列结构的示例。
图3例示了包括二极管和两个太阳能电池的太阳能电池阵列结构的另一示例，其中，二极管和其中一个太阳能电池设置在同一基板上。
具体实施方式
在图1中示出了本发明太阳能电池阵列结构的示例性的实施方式。该结构包括支撑基板1，例如，该支撑基板1由玻璃制成。在支撑基板1上以例如喷涂在支撑基板1上的铝层的形式设置有第一导热且导电的基板2。在基板2上形成涂层3和涂层3′，涂层3用于与太阳能电池4进行热连接和电连接，涂层3′用于与接触焊盘5进行热连接和电连接。类似地，在支撑基板1上设置有第二导热且导电的基板2’，其涂覆有涂层3″与3″′，在涂层3″上形成有第二太阳能电池4′，在涂层3″′上形成有第二接触焊盘5′。
此外，另一个导电基板6形成在支撑基板1上。在导电基板6上形成有二极管7，其充当太阳能电池4与4′的旁路二极管。电布线8、8′设置在太阳能电池4、4′与相应的接触焊盘5、5′之间。此外，电布线9、9′设置在接触焊盘5、5′与二极管7之间，且电布线9″、9″′分别设置在基板2和2′与基板6之间。可以用传统的薄线布线或厚线布线或带式绑定连接的连接来实现布线。此外，可以执行焊接以实现合适的布线。然而，包括基板2、2′、太阳能电池4、4′以及接触焊盘5、5′的两个太阳能电池阵列与二极管7电连接，实际上，大量的太阳能电池阵列可以由单个二极管来保护。二极管优选肖特基类型。太阳能电池4、4′各自可以是多结太阳能电池，其包括例如在不同波长范围展现出最佳吸收的三个电池。三电池结构可以包括例如具有带隙值为1.8eV的GalnP顶部电池层、具有带隙值为1.4eV的GaAs中间电池层以及具有带隙值为0.7eV的Ge底部电池层。
在所示示例中，一个单一的小型肖特基二极管能够为多个太阳能电池提供过压保护。具体地，相对于现有技术的太阳能电池阵列，根据本发明，原电池(Galvanicelement)的总数目与导致原电池的形成的不同工艺材料的数目能有效地减少。
在图2中示出了与图1中的实施方式类似的但具有不同的布线的实施方式。用相同的标号来指示已经在图1示出的相同的元件。例如，通过环氧银(silver epoxy)将二极管7附接到导电基板6′。此外，在同一基板6′上设置有接触焊盘10。在基板2与2′上分别设置有太阳能电池4与4′。通过布线11与11′，基板2与2′以及基板2与6′分别彼此电连接。此外，通过布线12建立焊盘5与5′之间的电连接，并且通过布线12′建立焊盘5与10之间的电连接。因此，尽管在图1中所示的示例实现了到旁路二极管的直接接合，但在图2中所示的示例实现了到与旁路二极管邻近的接触焊盘的接合。
图3例示了另一种实施方式，其中，二极管与其中一个太阳能电池设置在同一基板上。由图3可以看出，二极管与太阳能电池4设置在基板13上，且通过焊盘5彼此电连接。此外，通过连接焊盘5与5′的布线12′来建立与设置在基板2上的太阳能电池4的电连接(太阳能电池4通过另一布线连接到焊盘5′)。当使用合适的布线时，二极管也用作针对其它太阳能电池的旁路二极管。
先前讨论的所有实施方式并不旨在进行限制，而是作为例子来说明本发明的特征和优点。应当理解的是，某些或所有的上述特征也可以以不同的方式组合。

Claims (15)

1.一种太阳能电池阵列结构，该结构包括：
多个太阳能电池，所述多个太阳能电池设置在至少一个基板上；
多个接触焊盘，所述多个接触焊盘设置在所述至少一个基板上，所述多个太阳能电池中的每个太阳能电池对应一个接触焊盘；
电布线，所述电布线将所述多个太阳能电池中的每个太阳能电池与所述多个接触焊盘中的对应的一个接触焊盘相连接；以及
二极管，所述二极管与所述多个太阳能电池中的至少两个太阳能电池电连接，具体地，所述二极管与连接到所述多个太阳能电池中的至少两个太阳能电池的接触焊盘的对应的接触焊盘相连接。
2.根据权利要求1所述的太阳能电池阵列结构，其中，通过电绝缘粘合剂将所述接触焊盘设置在所述至少一个基板上，所述电绝缘粘合剂具体地是透明的粘合剂。
3.根据权利要求1或2所述的太阳能电池阵列结构，其中，所述接触焊盘不包括绝缘层。
4.根据前述权利要求中之一所述的太阳能电池阵列结构，其中，所述接触焊盘包括由铝、铜、青铜或黄铜制成的基部和/或由金、银、钯、铜、铝、镍、锡或锌制成的用于电连接的表面。
5.根据前述权利要求中之一所述的太阳能电池阵列结构，其中，所述二极管与至少两个所述接触焊盘电连接。
6.根据前述权利要求中之一所述的太阳能电池阵列结构，其中，所述二极管是肖特基二极管。
7.根据前述权利要求中之一所述的太阳能电池阵列结构，其中，所述至少一个基板是导热且导电的基板。
8.根据权利要求7所述的太阳能电池阵列结构，其中，所述至少一个基板包括铝或铝合金，或者由铝或铝合金构成。
9.根据前述权利要求中之一所述的太阳能电池阵列结构，其中，将所述至少一个基板直接地、无需粘合剂地设置在电绝缘支撑基板上，所述电绝缘支撑基板具体地是玻璃支撑基板。
10.根据前述权利要求中之一所述的太阳能电池阵列结构，其中，所述至少一个基板是平坦的铝或铝合金板，并且通过粘合剂设置在电绝缘支撑基板上，所述电绝缘支撑基板具体地是玻璃支撑基板。
11.根据权利要求9或10所述的太阳能电池阵列结构，其中，所述至少一个基板承载多于一个的太阳能电池。
12.根据权利要求9、10或11所述的太阳能电池阵列结构，其中，针对每个所述太阳能电池设置所述至少一个基板中的对应的一个基板，并且其中，每个基板或者它的涂层具有类似高斯的厚度分布，并且具体地，每个太阳能电池设置在对应的基板上的所述基板的厚度最大的区域处。
13.根据前述权利要求中之一所述的太阳能电池阵列结构，其中，所述至少一个基板被涂层涂覆，所述涂层由银、镍、锡、铜或适于用作导电粘合剂或焊料的功能性表面的任何其它材料或合金的一种或多种制成，或包含银、镍、锡、铜或适于用作导电粘合剂或焊料的功能性表面的任何其它材料或合金的一种或多种，并且所述涂层提供与所述太阳能电池和/或所述二极管的热连接和电连接。
14.根据权利要求13所述的太阳能电池阵列结构，其中，通过导电的粘合剂或焊料将所述太阳能电池和/或所述二极管设置在所述涂层上，所述导电的粘合剂或焊料具体地是银粘合剂或焊料。
15.一种聚光器光伏模块，所述聚光器光伏模块包括根据前述权利要求中之一所述的太阳能电池阵列结构。
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