CN202142565U - 供在集中太阳能系统中使用的太阳能电池模块 - Google Patents

供在集中太阳能系统中使用的太阳能电池模块 Download PDF

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CN202142565U
CN202142565U CN2011201549200U CN201120154920U CN202142565U CN 202142565 U CN202142565 U CN 202142565U CN 2011201549200 U CN2011201549200 U CN 2011201549200U CN 201120154920 U CN201120154920 U CN 201120154920U CN 202142565 U CN202142565 U CN 202142565U
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solar cell
solar
framework
optical element
strutting piece
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杨磊
苏尼尔·瓦伊德
米哈伊尔·卡茨
加里·赫林
菲利普·布卢门菲尔德
达明·布伊
约翰·纳吉瓦里
詹姆斯·福雷西
彼得·艾伦·扎瓦兹基
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Solaero Solar Power Inc
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Abstract

本实用新型涉及一种供在集中太阳能系统中使用的太阳能电池模块。一种具有太阳能电池接纳器的太阳能电池模块，其供在集中太阳能系统中使用，所述集中太阳能系统将太阳能集中到太阳能电池上以用于将太阳能转换为电。所述太阳能电池接纳器可包含安装在支撑件上且具有一个或一个以上III-V族化合物半导体层的太阳能电池。光学元件可定位在所述太阳能电池上方且具有入口背离所述太阳能电池而出口面向所述太阳能电池的光学通道。框架可定位在所述支撑件上方并围绕所述太阳能电池而延伸，其中所述框架具有在所述支撑件上方延伸并面向所述光学元件的内部侧面。封装物可定位在所述支撑件上方且容纳在所述光学元件与所述框架之间。所述封装物在与所述光学元件和所述框架的接触点处可具有增大的高度，且在远离所述光学元件和所述框架的所述接触点之间具有减小的高度。

Description

供在集中太阳能系统中使用的太阳能电池模块
技术领域
本实用新型涉及太阳能电池领域，且更明确地说，涉及一种供在集中太阳能系统中使用的太阳能电池模块。
背景技术
太阳能电池是用来将太阳能或辐射能转换为电。在历史上，已主要由硅(Si)太阳能电池来提供太阳能电力(在空间和陆地两者中)。然而，在过去数年来，高效III-V族多结太阳能电池的大量制造已使得能够考虑将此替代技术用于陆地电力生产。与Si相比，III-V族多结电池通常较抗辐射，且具有较大的能量转换效率，但其往往花费较多。一些目前的III-V族多结电池的能效超过27％，而硅技术通常仅达到17％的效率。在集中的情况下，一些目前的III-V族多结电池的能效超过37％。当在宇宙飞船或其它太阳能系统中首要需要非常高的电力或较小的太阳能电池阵列时，通常使用多结电池来代替Si基电池或与其混合组合，以减小电池阵列大小。
一般来说，多结电池为n/p极性(n-on-p polarity)，且由InGaP/(In)GaAs/Ge化合物组成。III-V族化合物半导体多结太阳能电池层可经由Ge衬底上的有机金属化学气相沉积(MOCVD)来生长。Ge衬底的使用允许在n-Ge和p-Ge之间形成结。太阳能电池结构可在平均质量密度约为86mg/cm2的100-mm直径(4英寸)Ge衬底上生长。
在一些多结电池中，中间电池是与GaAs电池形成对比的InGaAs电池。用于InGaAs中间层的铟浓度可在约1.5％的范围中。在一些实施方案中，此布置带来增加的效率。InGaAs层大体上完美地晶格匹配到Ge衬底。
不管所使用电池的类型，太阳能系统的已知问题是，个别太阳能电池可能会被损坏或被障碍物遮蔽。举例来说，太阳能电池暴露于恶劣的环境条件会造成发生损坏。具有一个或一个以上损坏的或被遮蔽的太阳能电池的面板的载流量减少，且来自与所述面板串联的其它面板的输出对损坏的或被遮蔽的太阳能电池施加反向偏压。在损坏的或被遮蔽的电池上的电压因此以反极性增加，直到在所述串联中的所有面板的全部输出电压施加到相关面板中损坏的或被遮蔽的电池为止。这致使损坏的或被遮蔽的电池崩溃。
由于供陆地应用的太阳能电池系统具有数千个太阳能电池，所以其电压输出正常处于数百伏特的范围中，且其电流输出处于数十安培的范围中。在这些输出功率水平上，如果太阳能电池端子不受保护，往往会发生呈火花形式的无法控制的放电，且这可导致对太阳能电池和对整个系统的损坏。
多结太阳能电池形成太阳能电池接纳器的一部分，所述太阳能电池接纳器可在集中器太阳能电池系统中使用。可在水、极热和湿度可能破坏性能且/或导致失效的环境中使用所述太阳能电池接纳器。已设立标准和测试资质认证来确保太阳能电池接纳器在使用期间满足最低要求。一个具体行业标准是IEC62108。太阳能电池接纳器应以满足这些标准的要求的方式构造以确保适当性能。
实用新型内容
本实用新型的一个方面是一种太阳能电池模块，其供在集中太阳能系统中使用以将太阳能转换为电，所述太阳能电池模块包含：外壳，其具有一连串的成对透镜；以及太阳能电池接纳器，其中透镜中的每一者沿外壳的上部部分而定位，且太阳能电池接纳器中的每一者沿外壳的下部部分而间隔开。所述太阳能电池接纳器包含：支撑件；太阳能电池，其安装在所述支撑件上并具有一个或一个以上III-V族化合物半导体层；以及光学元件，其定位于所述太阳能电池上方所述太阳能电池与成对透镜之间，并界定具有面向所述成对透镜的增大的入口和面向所述太阳能电池的减小的出口的光学通道，所述光学通道将太阳能集中到太阳能电池上。所述太阳能电池接纳器可包含框架，所述框架定位于所述支撑件上方，其中与太阳能电池相比，高出支撑件的高度较大。所述框架可围绕所述太阳能电池而延伸并在内部空间中封闭所述太阳能电池。封装物可容纳在光学元件与框架之间的内部空间内，并可覆盖所述支撑件和所述太阳能电池的若干部分。所述封装物可在所述光学元件和所述框架中的每一者处具有增大的外部边缘高度。
当然，本实用新型不限于以上特征和优点。在阅读以下详细描述和在查看附图之后，所属领域的技术人员将即刻认识到额外的特征和优点。
附图说明
下文将参考附图更全面地描述本实用新型，其中展示本实用新型的一些(但非全部)实施例。说明实施例的图式是不按比例的示意性表示。出于本描述和所附权利要求书的目的，所有范围包含所揭示的最大和最小点，且包含其中的任何中间范围，所述范围可能或者可能不会在本文明确列举。
图1是太阳能电池模块的实施方案的透视图。
图2是次级光学元件的实施方案的透视图。
图3是太阳能电池接纳器的实施方案的部分分解透视图。
图4是较详细说明图3的太阳能电池和金属化陶瓷衬底的部分分解透视图。
图5是太阳能电池、金属化陶瓷衬底和散热片沿图3的线X-X’的截面图。
图6是具有框架和封装物的太阳能电池接纳器的透视图。
图7是沿图6的线Y-Y’切开的横截面图。
图8是定位在框架内的封装物的横截面图。
图9是定位在框架内的封装物的横截面图。
图10是定位在框架内的封装物的横截面图。
具体实施方式
图1说明太阳能电池模块200的实施方案，所述太阳能电池模块200包括透镜阵列210和对应的太阳能电池接纳器100。透镜210中的每一透镜与太阳能电池接纳器100中的一者对准。太阳能电池模块200可包含各种数目的透镜210和太阳能电池接纳器100。图1包含具有在3x5阵列中对准的十五个透镜210和太阳能电池接纳器100的模块200。
透镜210形成于光学材料(例如，丙烯酸)的连续板211上。在一些实施方案中，板211的不形成为透镜210的区域被制成部分或完全不透明。通过从连续板211中形成透镜210，可实质上减少成本。第一，通过在较大的板上产生透镜210，生产成本减少。第二，组装成本减少，因为仅一个项目(即，透镜的板211)需要与太阳能电池接纳器100对准。在此实施方案中，板211位于外壳220的对准框架221的顶上。
可将一个或一个以上通风口228定位在外壳220中。开口228可经定位以促进空气流经外壳220。在一个实施例中，将开口228定位在外壳220的侧壁中，且在透镜210之下约3″。开口228的大小可改变。在一个实施例中，每一开口具有直径约为1″的圆形形状。盖子229可跨过开口228延伸且充当用以阻碍湿气和碎片进入外壳220中的过滤器。盖子229可由多种材料构成，包含(但不限于)戈尔(GORETEX)、尼龙和聚偏二乙烯。
框架221可包含多个框架对准元件，例如，孔。对准元件可有螺纹或者适于接纳扣件。板211可包含板对准元件，例如，销、螺丝或与框架对准元件对准并耦合的其它器具。框架对准元件和板对准元件经设置以使得通过将板对准元件与框架对准元件耦合，透镜210中的每一者与对应的太阳能电池接纳器100对准。对准元件通常位于由透镜210中的四个透镜界定的中心点中。在一个实施例中，对准元件位于由透镜210a、210b、210c以及210d界定的中心点中。另一对准元件可位于由四个其它透镜210界定的中心点中。可沿整个板211继续将对准元件设置在由四个透镜界定的中心点中的此样式。
在一些实施方案中，外壳220的底板表面222包括确保使太阳能电池接纳器100中的每一者位于预定位置中的对准零件。这些零件可与太阳能电池接纳器100中的每一者耦合。
在一些实施方案中，透镜210中的每一者是菲涅耳透镜。将对应的太阳能电池单元接纳器100定位在外壳220的相对端的表面222上。太阳能电池接纳器100中的每一者包含安置于对应的透镜210的光学路径中的对应的太阳能电池102，即，使得对应的太阳能电池102接收穿过对应的透镜210的光。在一些实施方案中，使用额外的光学元件来将太阳能电池放置在透镜的光学路径中。举例来说，次级光学元件104与太阳能电池接纳器100和透镜210的每一对对应。次级光学元件104聚集来自透镜210的光，并将其引导到太阳能电池接纳器100的太阳能电池102中。在一些实施方案中，太阳能电池接纳器100中的每一者具备对应的次级光学元件104。
另一光学元件包含定位于太阳能电池接纳器100与透镜210的对中的每一对之间的集中器106。集中器106将光集中到太阳能电池102上。
尽管与一些凸透镜相比，一些菲涅耳透镜可集中较多的阳光，但实施方案可使用集中入射阳光的任何类型的透镜210。举例来说，透镜210中的任何透镜可采取双凸透镜、平凸透镜或凸凹透镜的形式。透镜210还可包括多层抗反射涂层。在模块200中，透镜210中的每一者可为相同的，或者模块200可包含两个或两个以上不同的透镜210。
可基于透镜210的焦距来选择在包括透镜210的板211与对应的太阳能电池接纳器100的太阳能电池102之间测得的距离X。在一些实施方案中，外壳220经布置以使得每一相应的太阳能电池接纳器100的太阳能电池102安置于相应的透镜210的焦点处或焦点附近。在一些实施方案中，每一透镜210的焦距介于约25.4cm(10英寸)与76.2cm之间(30英寸)。在一些实施方案中，每一透镜210的焦距介于约38.1cm(15英寸)与50.8cm(20英寸)之间。在一些实施方案中，每一透镜210的焦距约为40.085cm(17.75英寸)。在一些实施方案中，每一透镜210的焦距改变，且外壳220在板211与表面222之间提供多个不同的距离(例如，大于和/或小于距离X的距离)。
外壳220和透镜板211可形成保护太阳能电池接纳器100免受环境影响的封闭内部空间。
透镜210的一些实施方案将入射阳光集中为正常集中度的1000倍(即，1000个太阳)或更多。其它实施方案可包含其它集中度。一般来说，太阳能到电的转换效率在集中照射的情况下增加。举例来说，在约1000个太阳下，单个太阳能电池接纳器可产生25瓦特或更多的电功率。在另一实例中，在约470或更多个太阳下，单个太阳能电池接纳器可产生14瓦特或更多的电功率。太阳能电池接纳器可产生的电功率的数量可依据(例如)太阳能电池特性(例如，大小、组成)和相关联的光学性质(例如，集中度、焦点、对准)的组合而改变。
在一些实施方案中，相应的太阳能电池接纳器100中的每一者的太阳能电池102是三结III-V族太阳能电池，其中三个子电池中的每一者串联布置。在使用多个太阳能电池模块200的应用中，太阳能电池模块200的接纳器100通常以串联方式电连接到一起。然而，其它应用可利用并联或串并联连接。举例来说，给定模块200内的接纳器100可以串联方式电连接到一起，但模块200以并联方式彼此连接。
如先前所阐释，次级光学元件(“SOE”)104可定位于透镜210与对应的太阳能电池102之间。SOE的实施方案说明于图2中。SOE 104安置于太阳能电池模块200的外壳220内，且通常经设计以收集由对应的透镜210中的一个透镜集中的太阳能。在一些实施方案中，太阳能电池接纳器100中的每一者具有相应的SOE 104。其它模块200可包含不足每一太阳能电池接纳器100包含SOE 104。
SOE 104包括光学元件401，所述光学元件401具有光学入口402和光学出口403；主体404；和安装突出部405。SOE 104经安装以使得光学元件401安置于对应的太阳能电池接纳器100的太阳能电池102上方。尽管其可依据实施方案而改变，但SOE 104经安装以使得光学出口403距太阳能电池102约0.5毫米(例如，尺寸406约为0.5毫米)。在一些实施方案中，安装突出部405耦合到外壳220的表面222。SOE 104可由金属、塑料、或玻璃或其它材料制成。
在一些实施方案中，光学元件401具有从入口402到出口403逐渐变细的大体上正方形的横截面。光学元件的内表面407朝向出口403而向下反射光。在一些实施方案中，内表面407涂覆有银或另一材料以获得高反射率。在一些情况中，由钝化涂层(例如，SiO2)保护反射涂层以免于氧化、失去光泽或腐蚀。从光学入口402到光学出口403的路径形成逐渐变细的光学通道，所述光学通道从对应的透镜210捕获太阳能并将其引到对应的太阳能电池102。如此实施方案中所示，SOE 104包括具有四个反射壁的光学元件401。在其它实施方案中，可使用不同的形状(例如，具三个侧面以形成三角形横截面)。
在理想条件下，与SOE 104相关联的对应的透镜210将光直接聚焦到太阳能电池102，而没有光撞到SOE 104。在大多数情况下，透镜210不将光直接聚焦到太阳能电池102上。这可能因多种起因而发生，包含(但不限于)折射透镜设计的色差(chromaticaberration)、在构造期间太阳能电池102相对于透镜210未对准、在操作期间因跟踪器误差而未对准、结构挠曲以及风荷载。因此，在大多数条件下，透镜210对光聚焦，以使其远离SOE 104而反射。理想的设置与未对准的设置之间的差异可为定位透镜210时小于1度的细小变化。SOE 104因此充当光溢出捕获器以在当对应的透镜210不直接将光聚焦到太阳能电池102上的情况下，致使更多的光到达太阳能电池102。SOE 104可包含反射性多层中间区域，例如，在2009年3月12日申请的序号为12/402,814的美国专利申请案中所揭示的种类，所述申请案的全文以引用的方式并入到本文中。
反射性多层中间区域可由不同的材料形成，且具有不同的光学特性，以使得远离SOE 104并传输到太阳能电池102的光束的反射率优化整个入射太阳光谱中在太阳能电池102的表面上的总辐照。举例来说，在一些实施方案中，内表面407可涂覆有银或另一材料，以获得高反射率。在一些情况中，由钝化涂层(例如，SiO2)保护反射涂层以使SOE 104受保护而免于氧化、失去光泽或腐蚀。SOE 104还可使光均匀化(例如，混合)。在一些情况下，其还具有一些集中效果。
在一些实施方案中，光学入口402是正方形的且约为49.60mmx49.60mm(尺寸408)，光学出口是正方形的且约为9.9mmx9.9mm(尺寸409)，且光学元件的高度约为70.104mm(尺寸410)。尺寸408、409和410可随着太阳能电池模块200和太阳能电池接纳器100的设计而改变。举例来说，在一些实施方案中，光学出口403的尺寸约与太阳能电池102的尺寸相同。对于具有这些尺寸的SOE 104，半倾斜角度为15.8度。
太阳能电池102中的每一者可为三结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、中间电池和底部电池。在另一实施例中，太阳能电池102是多结太阳能电池，其具有n/p极性且由InGaP/(In)GaAs III-V族化合物在Ge衬底上构成。在每一情况中，太阳能电池102经定位以从SOE 104和/或对应的透镜210接收聚焦的太阳能。
抗反射涂层可安置于太阳能电池102上。所述抗反射涂层可为在某一波长范围(例如，0.3μm到1.8μm)提供低反射率的多层抗反射涂层。抗反射涂层的实例是双层TiOx/Al2O3电介质堆叠。
如图3中所说明，SOE 104的突出部405可经配置以用于经由一个或一个以上扣件118将SOE 104附接到托架116。提供托架116以用于经由个或一个以上扣件122将SOE 104安装到散热片120。托架116是导热的，使得在操作期间由SOE 104产生的热能可传送到散热片120并耗散。
在如图3和图4中所示的一个实施例中，集中器106安置于SOE 104的出口403与太阳能电池102之间。集中器106优选为玻璃，且具有光学入口108和光学出口110。在一个实施例中，集中器106为固体玻璃。集中器106放大从SOE 104出来的光，并引导经放大的光朝向太阳能电池102。在一些实施方案中，集中器106具有从入口108到出口110逐渐变细的大体上正方形的横截面。在一些实施方案中，集中器106的光学入口108是正方形的，且约为2cmx2cm，且光学出口110约为0.9cmx0.9cm。集中器106的尺寸可随着太阳能电池模块200和太阳能电池接纳器100的设计而改变。举例来说，在一些实施方案中，光学出口110的尺寸约与太阳能电池102的尺寸相同。在一个实施例中，集中器106是2X集中器。集中器106的底部表面可通过使用例如硅树脂粘合剂等粘合剂151而直接附接到太阳能电池102的上部表面。太阳能电池102通过光伏效应将进入的阳光直接转换为电。
在如图1和图3所示的一些实施例中，SOE 104和集中器106都沿着对应的透镜210与太阳能电池102之间的光学路径而定位。其它实施例可包含沿所述光学路径而定位的这些光学元件中的仅一个。其它实施例可不包含沿所述光学路径而定位的这些元件中的任一个。在模块200内，透镜210/太阳能电池102对中的每一对可包含用于引导光的相同或不同的元件组合。
如图3和图4中所说明，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是半导体装置，例如肖特基(Schottky)旁路二级管或外延生长的p-n结。出于说明的目的，旁路二极管124是肖特基旁路二级管。提供外部连接端子125和127以用于将太阳能电池102和二极管124连接到其它装置(例如，邻近的太阳能电池接纳器)(未说明)。
通过考虑串联连接的多个太阳能电池102可理解旁路二极管124的功能性。可将每一太阳能电池102想象为电池，其中二极管124中的每一者的阴极连接到相关联的“电池”的正极端子，且二极管124中的每一者的阳极连接到相关联的“电池”的负极端子。当串联连接的太阳能电池接纳器100中的一者被损坏或遮蔽时，其电压输出降低或消除(例如，在与二极管124相关联的阈值电压之下)。因此，相关联的二极管124变得前向偏压，且旁路电流仅流经所述二极管124(而并非太阳能电池102)。以此方式，未损坏或未被遮蔽的太阳能电池接纳器100继续从由那些太阳能电池接收的太阳能来产生电。如果没有旁路二极管124，大体上由其它太阳能电池接纳器产生的所有电将穿过被遮蔽或损坏的太阳能电池接纳器，毁坏所述被遮蔽或损坏的太阳能电池接纳器，并在(例如，面板或阵列)内产生断路。
太阳能电池接纳器100还包含陶瓷衬底126(例如氧化铝衬底)，以用于太阳能电池102和用于耗散太阳能电池102在操作期间所产生的热的散热片120的安装。图4和图5较详细地说明太阳能电池102和陶瓷衬底126。陶瓷衬底126具有金属化的上部和下部表面128和130。陶瓷衬底126的两个表面128和130都被金属化，以提高陶瓷衬底126的传热能力，从而使得太阳能电池接纳器100能够更充分地处置因太阳能电池操作条件的突然改变而发生的快速温度变化。举例来说，太阳能电池102在将光转换为电时产生热能。使陶瓷衬底126的上部和下部表面128和130两者金属化允许将热能从太阳能电池102较快地传送到散热片120以供耗散。当太阳能电池102变得忽然被遮蔽时发生相反的情况。即，太阳能电池102停止产生电并迅速冷却，SOE 104也一样。陶瓷衬底126的金属化的上部和下部表面128和130通过将热能从散热片120传送到太阳能电池102(且视热条件而定，还传送到SOE 104)来防止太阳能电池102过快冷却。增加太阳能电池接纳器100的传热能力减少了在快速温度变化期间给予太阳能电池102与陶瓷衬底126之间界面的应力量，从而确保可靠的太阳能电池与衬底界面(solarcell-to-substrate interface)。
陶瓷衬底126的金属化上部表面128与太阳能电池102接触，且具有用于提供到太阳能电池102的隔离导电路径的单独导电区域132和134。第一导电区域132为太阳能电池102提供阳极电接触点，且第二导电区域134为太阳能电池102提供阴极电接触点。太阳能电池102具有在图4中不可见但在图5的横截面中可见的导电下部表面136，导电下部表面136定位在陶瓷衬底126的金属化上部表面128的第一导电区域132上并连接到所述第一导电区域132。太阳能电池102的相对上部表面138具有连接到陶瓷衬底126的第二导电区域134的导电接触区140。
在一个实施例中，太阳能电池102的导电下部表面136形成太阳能电池102的阳极端子，且安置于太阳能电池102的上部表面138处的导电接触区140形成阴极端子。根据此实施例，太阳能电池102的导电下部表面136定位在陶瓷衬底126的第一导电区域132上，且与第二导电区域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的第一导电区域132至少部分地在三个侧面上由第二导电区域134沿陶瓷衬底126的外围区域所围绕。
在一个实施例中，安置于太阳能电池102的上部表面138处的导电接触区140占据太阳能电池102的周边。在一些实施方案中，上部导电接触区140可较小或较大，以适应所要的连接类型。举例来说，上部导电接触区140可接触太阳能电池102的仅一个、两个或三个侧面(或其若干部分)。在一些实施方案中，将上部导电接触区140制造得尽可能小，以使将太阳能转换为电的区最大化，而同时允许电连接。尽管太阳能电池102的具体尺寸将依据应用而变化，但标准尺寸约为1cm2。举例来说，一套标准的尺寸可为整体约12.58mmx12.58mm、约0.160mm厚以及总有效面积约为108mm2。举例来说，在约12.58mmx12.58mm的太阳能电池102中，上部导电接触区140可为约0.98mm宽，且有效面积可为约10mmx10mm。
太阳能电池102的上部导电接触区140可由例如铜、银和/或涂金银等多种导电材料形成。在此实施方案中，是太阳能电池102的n导电阴极(即，发射极)侧接收光，且因此，上部导电接触区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的上部导电接触区140经由一个或一个以上接合线142而线接合到陶瓷衬底126的金属化上部表面128的第二导电区域134。在具体实施例中所利用的接合线142的数目可尤其与由太阳能电池102产生的电流量有关。一般来说，电流越大，所使用的接合线142的数目就越大。
旁路二极管124将陶瓷衬底126的金属化上部表面128的第一导电区域132耦合到第二导电区域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的第一导电区域132而连接到太阳能电池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的第二导电区域134而电连接到太阳能电池102的阴极端子。如上文所描述，太阳能电池102的阳极端子由太阳能电池102的下部导电表面136形成，且在图4中不可见但在图5的横截面中可见。也如上文所描述，太阳能电池102的阴极端子由太阳能电池102的上部导电接触区140形成。
安置于陶瓷衬底126的金属化上部表面128上的外部连接端子125、127提供装置到太阳能电池102和旁路二极管124的电耦合。在一些实施方案中，连接器端子125和127对应于阳极和阴极端子，且经设计以接纳插头(未图示)，以供连接到邻近的太阳能电池接纳器。
陶瓷衬底126的上部表面128可通过将金属化层132和134附接到衬底而金属化。在一个实施例中，孔144形成于金属化层132、134中。图4展示具有附接到上部衬底表面128的两个金属化层132和134的陶瓷衬底126(下部金属化表面在图4中不可见，但在图5的横截面中可见)。在陶瓷衬底102上可形成对应的凸起。所述凸起至少部分地坐落于形成于金属化层132和134中的孔144中。接着用焊料或其它类型的接合材料(例如，粘合剂)来填充金属化层132和134中的孔144，从而将金属化层132和134附接到陶瓷衬底126的上部表面128。可以类似方式来金属化陶瓷衬底126的下部表面130。或者，在陶瓷衬底126上不提供凸起，且衬底在正常制造公差内相对较平。
图5说明太阳能电池接纳器100的太阳能电池102、陶瓷衬底126和散热片120沿在图3中标记为X-X’的线的横截面图。为了易于说明，在图5中未说明SOE 104、光集中器106和端子125、127。如上文所描述，陶瓷衬底126的上部和下部表面128和130可具有凸起，所述凸起至少部分地坐落于形成于金属化层132、134和148中的孔144中，以用于将金属化层附接到陶瓷衬底126。或者，陶瓷衬底126在正常制造公差内相对较平坦。在两者中的任一情况中，陶瓷衬底126的上部和下部表面被金属化。如上文所描述，衬底126的上部金属化表面128具有单独的导电区域132和134，以用于提供到太阳能电池102的电隔离阳极和阴极连接。
太阳能电池102具有连接到陶瓷衬底126的金属化上部表面128的导电区域132的导电下部表面136。在一个实施例中，太阳能电池102的导电下部表面136形成太阳能电池102的阳极端子，且安置于太阳能电池102的上部表面138处的导电接触区140形成太阳能电池102的阴极端子。太阳能电池102的导电下部表面136定位于陶瓷衬底126的金属化上部表面128的第一导电区域132上，且与第二导电区域134电隔离，以确保太阳能电池102的正确操作。
陶瓷衬底126的下部表面130还具有用高导热附接媒介150(例如，金属填充的环氧树脂粘合剂或焊料)接合到散热片120的金属化层148。用金属来填充例如硅树脂等环氧树脂粘合剂增加陶瓷衬底126与散热片120之间的界面的导热性，从而进一步改善太阳能电池接纳器100的传热特性。在一个实施例中，高导热附接媒介150是厚度tepoxy为约1密尔到3密尔的金属填充的环氧树脂粘合剂。金属填充的环氧树脂粘合剂可施加到陶瓷衬底126的下部金属化表面130、散热片120或两者上，且接着固化以将散热片120接合到衬底126。在一个实施例中，散热片120是如图3中所示的单片挤压铝散热片。
可通过提供金属化陶瓷衬底126和将太阳能电池102的导电下部表面136连接到衬底126的金属化上部表面128的第一导电区域132来制造太阳能电池接纳器100。安置于太阳能电池102的上部表面138处的导电接触区140(例如，经由一个或一个以上接合线142)连接到陶瓷衬底126的金属化上部表面128的第二导电区域134。散热片120用金属填充的环氧树脂粘合剂150接合到陶瓷衬底126的下部金属化表面130。
如图6中所说明，框架170可附接到陶瓷衬底126的金属表面128，并围绕太阳能电池102和相关组件而延伸。框架170包含开放式中央区域174并形成针对覆盖太阳能电池接纳器100的一部分的封装物160的坝。封装物160保护太阳能电池接纳器100免受例如水(例如，雨、冰、雪)温度变化和湿度等环境因素的影响。框架170还形成用于提供离轴光束保护并用于密封连接端子125、127的遮罩。
当在延伸穿过底部和顶部侧面172、173的平面中观看时，框架170可包含各种横截面形状。图7包含具有相对的内部和外部侧面171、177和相对的底部和顶部侧面172、173的矩形形状。视应用而定，框架170还可包含多种其它横截面形状。在一个特定实施例中，框架170包含不规则的形状。
如图7中所说明，框架170可为实心的，或如图9中所说明，可为中空的，具有开放式内部空间178。图9包含完全包围内部空间178的框架170。在另一实施例(未说明)中，框架170基本上包围内部空间178的三个侧面，其中内部空间178暴露于底部侧面上(即，与顶部侧面173相对)。
框架170可由一个或一个以上构件构成。在一个实施例中，框架170由两个大体上L形的构件构成。框架170的外部和内部形状可依据应用而变化。外部形状由框架170的外部侧面177形成，且内部形状由内部侧面171形成。图6包含具有正方形内部和外部形状的框架170。内部和外部形状还可包含(但不限于)矩形、圆形、椭圆形和梯形。另外，内部和外部形状可相同或不同。框架170可由多种材料(包含陶瓷)构成。
图7说明定位于框架170内且在太阳能电池接纳器100的一部分上方的封装物160的横截面图。封装物160延伸过集中器106的一部分、陶瓷衬底126的金属化上部表面128、太阳能电池102的若干部分(包含接触区140)和在接触区140与金属化上部表面128之间延伸的接合线142。将集中器106接合到太阳能电池102的透光粘合剂151阻止封装物160在集中器106与太阳能电池102之间延伸。
封装物160最初呈流体形式，以流到框架170内的各种区中。封装物160进一步固化到较固体的状态，以永久保护太阳能电池接纳器100。在一个实施例中，封装物160是可从道康宁公司(Dow Corning Corporation)购得的SYLGARD 184。
图8是说明框架170和封装物160的尺寸和定位的类似于图7的简化截面图。框架170包含在底部侧面172与顶部侧面173之间测得的高度a。高度“a”允许顶部侧面173沿集中器106的中间部分而定位，并与集中器106的底部侧面109相比，从上部金属表面128向外延伸较大的距离。框架170的内部侧面171面向集中器106，且可为平坦的并大体上垂直于上部金属表面128而对准。内部侧面171距集中器106的底部和中间侧面109、111的交叉点距离“b”而定位。在一些实施例中，距离b可介于2.0mm到5.0mm之间。
框架170与集中器106之间的距离和封装物160的物理特性在封装物160被放置在内部空间178内时在封装物160中引起高表面张力。这致使封装物160攀爬集中器106的中间侧面111和框架170的内部侧面171。这给予封装物160具有增大的内部和外部边缘161、162和减小的中间部分163的大体上凹形的上部表面。从上部金属表面128测得的内部和外部边缘161、162的高度介于约1.0mm与3.0mm之间。在数个具体实施例中，所述高度介于约1.75mm与1.90mm之间。封装物160在内部边缘161处的高度可能不同于在外部边缘162处的高度。中间部分163的高度介于0.50mm到2.0mm之间。在数个具体实施例中，所述高度介于约0.65mm与0.85mm之间。
如图7和图8中所说明，封装物160高出上部金属表面128的高度足以覆盖接合线142(其高出表面128约0.35mm和0.40mm之间而延伸)。封装物160高出接合线142的高度介于约0.20mm与0.50mm之间。在数个具体实施例中，高出接合线142的高度介于约0.32mm与0.41mm之间。
图7包含完全定位于衬底126的上部表面128上方的框架170。如图9中所说明，框架170还可向外延伸超出表面128。框架170以外部侧面177从表面128横向向外定位并位于散热片120上方的方式而定位。材料180位于框架170与散热片120之间。材料180可为用于将框架170附接到散热片120的粘合剂和/或用以防止封装物160的泄漏的密封剂。
如图9中所说明，在太阳能电池接纳器100的一个实施例中，附接媒介150是SYLGARD 577。SYLGARD 577还用作下部金属化表面130周围的边缘处理，且用作框架170与散热片120之间的材料180。用材料181填充框架170的内部空间178。此材料181还可定位在框架170的外部侧面177周围。在一个实施例中，材料181是SS-109硅树脂。
在另一实施例(未说明)中，框架170完全定位于散热片120上方且不延伸过表面128。
在如图10中所说明的一个实施例中，框架170的内部侧面171包含远远地与集中器106成角度的成角度部分175。成角度部分175从沿着内部侧面171的中间点延伸到框架170的顶部侧面173。在一个具体实施例中，侧面175的角度大体上匹配集中器106的中间侧面111的角度。这允许侧面175和111大体上平行。成角度部分175控制外部边缘162的高度。成角度部分175还可控制内部边缘161的高度。在一个实施例中，内部边缘161的高度与内部侧面171与成角度部分175之间的交叉点处的高度相同。
成角度部分175可完全在框架170周围延伸，或可沿框架170的仅一个或一个以上的有限部分而设置。在一个实施例中，第一成角度部分175沿框架170的第一部分175而延伸，且面向矩形集中器106的第一面，且第二成角度部分175沿框架170的相对第二部分延伸，并面向矩形集中器的第二面。成角度部分175的角度可沿着框架170的各种部分而相同或可变化。
框架170可定位于太阳能电池接纳器100的一个或一个以上组件上方。图6包含定位在连接端子125、127上方的框架170(未在图4中说明)。框架170进一步包含开口176，开口176接纳与连接端子125、127连接的引线190。这些开口176可仅从外部侧面177向内延伸并在框架170的内部远离内部侧面171而终止，以针对封装物160而防止可能的泄漏位置。框架170可进一步延伸过旁路二极管124。框架170的底部侧面172可包含适应各种组件的断路器。在这些各种实施例中，框架170的内部侧面171定位在组件与太阳能电池102之间，以提供用于封装物160的表面且防止封装物的泄漏。
框架170可围绕集中器106和太阳能电池102而居中。或者，框架170可偏离中心，其中框架170的一个部分比另一部分更靠近集中器106和太阳能电池102。
在一些实施例中，框架170的中心区域174是单个部分。封装物160可被引入到中心区域174中，且接着允许流经区域174并覆盖各种组件。中心区域174还可分成两个或两个以上单独的部分。太阳能电池接纳器100的构造要求封装物160分别引入到所述部分中的每一者中。
在组装期间，框架170附接到衬底126和/或散热片120。粘合剂可用于附接，且还用以防止封装物160在随后的组装步骤期间泄漏。
在附接框架170之后，将封装物160(其可为基于硅树脂的)引入到内部空间178中。封装物160具有表面张力，所述表面张力致使外部边缘处的高度增加。在引入之后，封装物160通过加热或其它合适的过程来固化。
太阳能电池102可为具有以堆叠布置提供的多个太阳能子电池的多结III-V族装置。太阳能电池102可包含具有用以最大程度地吸收太阳能的带隙的上部、中间以及下部子电池。一种可应用太阳能电池揭示于2008年4月18日申请的序列号为12/148,553的美国申请案，所述申请案的全文以引用的方式并入到本文中。
托架116(图3)可延伸过框架170，其中扣件122附接到散热片120在框架170外部的若干点处。托架116的下部侧面可与框架170的顶部侧面173相抵接触或在其上方。或者，托架116可定位在框架170的中心区域174内。
在本文所描述的各种实施方案中，使用了三结III-V族化合物半导体太阳能电池，但可视应用而定使用其它类型的太阳能电池。太阳能电池102可由例如硅(包含非晶、纳米晶或原晶)、碲化镉、CIGS(铜铟镓硒)、CIS(铜铟硒(CuInSe2)的黄铜矿膜)、砷化镓(例如，GaAs多结))、光吸收染料(例如，有机金属钌染料)或有机半导体(例如，聚亚苯基亚乙烯基(polyphenylene vinylene)、铜酞菁或碳富勒烯)等制成。
由于单个太阳能电池模块200可能不会产生用于给定应用的充足的电，所以可将两个或两个以上太阳能电池模块200组合在一起成为阵列。这些阵列有时被称为“面板”或“太阳能面板”。
尽管已展示和描述了本实用新型的具体实施例，但所属领域的技术人员将了解，基于本文中的教示，在不脱离本实用新型以及其较宽广方面的情况下，可作出改变和修改，因此，所有属于本实用新型范围内的此类改变和修改将涵盖在所附权利要求书的范围内。此外，应了解，本实用新型仅由所附权利要求书界定。
所属领域的技术人员将了解，一般来说，在本文中且尤其在其所附权利要求书(例如，所附权利要求书的主体)中所使用的术语通常表示“开放式”术语(例如，术语“包含”应被解释为“包含但不限于”、术语“具有”应被解释为“至少具有”、术语“包含了”应被解释为“包含了但不限于”、“包括”以及其变体例如“包括了”和“正包括”应被认为处于开放的包含性的含义，即“包含但不限于”等)。所属领域的技术人员将进一步了解，如果特定数目的经引导的权利要求陈述是既定的，那么此意图将在权利要求书中明确陈述，且在无此类陈述的情况下便不存在此类意图。举例来说，作为对理解的辅助，所附权利要求书可使用引导性短语“至少一个”和“一个或一个以上”来引导权利要求陈述。然而，此类短语的使用不应被解释为暗示由不定冠词“一”引导的权利要求陈述将含有此类经引导的权利要求陈述的任何特定权利要求限于含有仅一个此类陈述的发明，即使在同一权利要求包含引导性短语“一个或一个以上”或“至少一个”以及例如“一”等不定冠词(例如，“一”通常应被解释为指“至少一个”或“一个或一个以上”)时也是如此；使用定冠词来引导权利要求陈述也是如此。另外，即使明确陈述了特定数目的经引导的权利要求陈述，所属领域的技术人员也将认识到，此类陈述通常应被解释为指至少所陈述的数目(例如，无修饰的陈述“两项陈述”在没有其它修饰成分的情况下通常指至少两项陈述，或两项或两项以上陈述)。

Claims (9)

1.一种太阳能电池模块，其用于在集中太阳能系统中以将太阳能转换为电，其特征在于所述太阳能电池模块包含：外壳，其具有一连串的成对透镜；以及太阳能电池接纳器，其中所述透镜中的每一者沿所述外壳的上部部分而定位，且所述太阳能电池接纳器中的每一者沿所述外壳的下部部分而间隔开；所述太阳能电池接纳器包含：支撑件；太阳能电池，其安装在所述支撑件上并包括一个或一个以上III-V族化合物半导体层；以及光学元件，其定位于所述太阳能电池上方、所述太阳能电池与所述成对透镜之间，并界定具有面向所述成对透镜的增大的入口和面向所述太阳能电池的减小的出口的光学通道，所述光学通道将所述太阳能集中到所述太阳能电池上，所述太阳能电池接纳器包括：
框架，其定位于所述支撑件上方，且具有比所述太阳能电池更高出所述支撑件的高度，所述框架围绕所述太阳能电池而延伸且在内部空间中将所述太阳能电池封闭；以及
封装物，其容纳在所述光学元件与所述框架之间的所述内部空间内，并覆盖所述支撑件和所述太阳能电池的若干部分，所述封装物在所述光学元件和所述框架中的每一者处具有增大的外部边缘高度。
2.根据权利要求1所述的太阳能电池模块，其特征在于所述外部边缘高度处于约1.0mm到3.0mm之间的范围中，且所述封装物的中间部分的高度处于约0.50mm到1.0mm之间的范围中。
3.根据权利要求2所述的太阳能电池模块，其特征在于所述光学元件处的所述外部边缘高度不同于所述框架处的所述外部边缘高度。
4.根据权利要求1所述的太阳能电池模块，其特征在于所述框架包含凹进的底部侧面，所述底部侧面面对所述支撑件以延伸过第一和第二电端子，所述电端子安装在所述支撑件上并形成各自具有插座以耦合到邻近的太阳能电池接纳器的阳极和阴极连接。
5.根据权利要求1所述的太阳能电池模块，其特征在于其进一步包括在所述太阳能电池与所述支撑件之间延伸的接合线，所述接合线被所述封装物完全覆盖。
6.根据权利要求5所述的太阳能电池模块，其特征在于所述封装物覆盖所述接合线，且以高出所述接合线处于约0.20mm到0.50mm之间的范围中的高度而延伸。
7.根据权利要求1所述的太阳能电池模块，其特征在于所述框架包含内部侧面，所述内部侧面在所述支撑件上方延伸，并面向所述光学元件，其中所述内部侧面距离所述光学元件约2.0mm到5.0mm之间而定位。
8.根据权利要求1所述的太阳能电池模块，其特征在于所述框架包含中空内部，所述中空内部以材料填充以防止所述封装物的泄漏。
9.根据权利要求1所述的太阳能电池模块，其特征在于所述支撑件安装在散热片上，且所述框架的至少一部分直接定位在所述散热片上方且远离所述支撑件。
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