US20090199891A1 - Solar cell receiver for concentrated photovoltaic system for iii-v semiconductor solar cell - Google Patents
Solar cell receiver for concentrated photovoltaic system for iii-v semiconductor solar cell Download PDFInfo
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- US20090199891A1 US20090199891A1 US12/264,369 US26436908A US2009199891A1 US 20090199891 A1 US20090199891 A1 US 20090199891A1 US 26436908 A US26436908 A US 26436908A US 2009199891 A1 US2009199891 A1 US 2009199891A1
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Images
Classifications
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- H01L31/02—Details
- H01L31/02002—Arrangements for conducting electric current to or from the device in operations
- H01L31/02005—Arrangements for conducting electric current to or from the device in operations for device characterised by at least one potential jump barrier or surface barrier
- H01L31/02008—Arrangements for conducting electric current to or from the device in operations for device characterised by at least one potential jump barrier or surface barrier for solar cells or solar cell modules
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
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- H02S40/00—Components or accessories in combination with PV modules, not provided for in groups H02S10/00 - H02S30/00
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- H01L31/04—Semiconductor 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
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- H01L31/04—Semiconductor 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
- H01L31/042—PV modules or arrays of single PV cells
- H01L31/05—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells
- H01L31/0504—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module
- H01L31/0508—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module the interconnection means having a particular shape
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- H01L31/04—Semiconductor 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
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- H01L31/04—Semiconductor 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
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- H01L31/04—Semiconductor 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
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- H01L31/0543—Optical elements directly associated or integrated with the PV cell, e.g. light-reflecting means or light-concentrating means comprising light concentrating means of the refractive type, e.g. lenses
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- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L31/00—Semiconductor 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
- H01L31/04—Semiconductor 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
- H01L31/054—Optical elements directly associated or integrated with the PV cell, e.g. light-reflecting means or light-concentrating means
- H01L31/0547—Optical 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
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02S—GENERATION OF ELECTRIC POWER BY CONVERSION OF INFRARED RADIATION, VISIBLE LIGHT OR ULTRAVIOLET LIGHT, e.g. USING PHOTOVOLTAIC [PV] MODULES
- H02S99/00—Subject matter not provided for in other groups of this subclass
-
- Y—GENERAL 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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
- Y02E10/52—PV systems with concentrators
-
- Y—GENERAL 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
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
- Y02E10/544—Solar cells from Group III-V materials
Definitions
- This disclosure relates to a solar cell receiver for a concentrated photovoltaic system design for a III-V compound semiconductor multijunction solar cell.
- Solar energy is one technology for power generation that is clean, quiet and renewable. It is also plentiful: with an average of roughly 125,000 terawatts of solar energy reaching the planet at any given time, solar technology can potentially generate a significant amount of energy.
- Solar cells are used to convert solar or radiant energy into electricity.
- a plurality of solar cells are disposed in an array or panel, and a solar energy system typically includes a plurality of such panels.
- the solar cells in each panel are usually connected in series, and the panels in a given system are also connected in series, with
- III-V multijunction cells are generally more radiation resistant and have greater energy conversion efficiencies, but they tend to cost more.
- Some current III-V multijunction cells have energy efficiencies that exceed 27%, whereas silicon technologies generally reach only about 17% efficiency. Under concentration, some current III-V multijunction cells have energy efficiencies that exceed 37%.
- the multijunction cells are of n-on-p polarity and are composed of InGaP/(In)GaAs/Ge compounds.
- III-V compound semiconductor multijunction solar cell layers can be grown via metal-organic chemical vapor deposition (MOCVD) on Ge substrates.
- MOCVD metal-organic chemical vapor deposition
- the use of the Ge substrate permits a junction to be formed between n- and p-Ge.
- the solar cell structures can be grown on 100-mm diameter (4 inch) Ge substrates with an average mass density of about 86 mg/cm 2 .
- the epitaxial layer uniformity across a platter that holds 12 or 13 Ge substrates during the MOCVD growth process is better than 99.5%. Each wafer typically yields two large-area solar cells.
- the cell areas that are processed for production typically range from 26.6 to 32.4 cm 2 .
- the epi-wafers can be processed into complete devices through automated robotic photolithography, metallization, chemical cleaning and etching, antireflection (AR) coating, dicing, and testing processes.
- the n- & p-contact metallization is typically comprised of predominately Ag with a thin Au cap layer to protect the Ag from oxidation.
- the AR coating is a dual-layer TiO x /Al 2 O 3 dielectric stack, whose spectral reflectivity characteristics are designed to minimize reflection at the coverglass-interconnect-cell (CIC) or solar cell assembly (SCA) level, as well as, maximizing the end-of-life (EOL) performance of the cells.
- CIC coverglass-interconnect-cell
- SCA solar cell assembly
- the middle cell is an InGaAs cell as opposed to a GaAs cell.
- the indium concentration may be in the range of about 1.5% for the InGaAs middle cell. In some implementations, such an arrangement exhibits increased efficiency.
- the InGaAs layers are substantially perfectly lattice-matched to the Ge substrate.
- a known problem with solar energy systems is that individual solar cells can become damaged or shadowed by an obstruction. For example, damage can occur as a result of exposure of a solar cell to harsh environmental conditions.
- the current-carrying capacity of a panel having one or more damaged or shadowed solar cells is reduced, and the output from other panels in series with that panel reverse biases the damaged or shadowed cells.
- the voltage across the damaged or shadowed cells thus increases in a reverse polarity until the full output voltage of all of the panels in the series is applied to the damaged or shadowed cells in the panel concerned. This causes the damaged or shadowed cells to breakdown.
- Another disadvantage of known solar cell receivers is that, owing to the need for such a receiver to generate 10 watts of power at 1000 volts for an extended period of up to, or exceeding, twenty years, there is a danger of sparking at various points on the receiver or at the electrical terminals which connect one receiver of a solar cell system to adjacent receivers.
- a solar cell module comprises a solar cell receiver having a multijunction III-V compound semiconductor solar cell, a secondary optical element and a lens to concentrate incident light onto the solar cell.
- FIG. 1 is a perspective view of an implementation of a solar panel including apparatus for generating electricity from solar energy.
- FIG. 2A is a perspective view of an implementation of a solar cell module.
- FIG. 2B is a perspective view of an implementation of a secondary optical element.
- FIG. 3 is a circuit diagram of the solar cell receiver of FIG. 4 .
- FIG. 4 is a perspective view of an implementation of a solar cell receiver, which forms part of the solar cell module of FIG. 2A .
- FIG. 5 is a cross-section taken on line A-A of FIG. 4 .
- FIG. 6 is a view of the bottom of an implementation of a solar cell receiver.
- FIGS. 7A , 7 B and 7 C depict an alternative implementation of a solar cell.
- FIG. 8 depicts an alternative implementation of a solar cell receiver.
- Solar cell receivers convert solar energy into electricity.
- solar cell receivers generally comprise one or more solar cells.
- a solar cell may be made from, e.g., silicon (including amorphous, nanocrystalline, or protocrystalline), cadmium telluride, CIGS (copper indium gallium diselenide), CIS (chalcopyrite films of copper indium selenide (CuInSe 2 )), gallium arsenide (e.g., GaAs multijunctions), light absorbing dyes (e.g., ruthenium metalorganic dye), or organic semiconductors (e.g., polyphenylene vinylene, copper phthalocyanine or carbon fullerenes).
- silicon including amorphous, nanocrystalline, or protocrystalline
- CIGS copper indium gallium diselenide
- CIS chalcopyrite films of copper indium selenide (CuInSe 2 )
- gallium arsenide e.g., GaAs multijunctions
- light absorbing dyes
- a triple-junction III-V compound semiconductor solar cell is employed, but other types of solar cells could be used depending upon the application.
- Solar cell receivers often contain additional components, e.g., connectors for coupling to an output device or other solar cell receivers.
- a solar cell receiver may be implemented as part of a solar cell module.
- a solar cell module may include a solar cell receiver and a lens coupled to the solar cell.
- the lens is used to focus received light onto the solar cell. As a result of the lens, a greater concentration of solar energy can be received by the solar cell.
- the lens is adapted to concentrate solar energy by a factor of 400 or more. For example, under 500-Sun concentration, 1 cm 2 of solar cell area produces the same amount of electrical power as 500 cm 2 of solar cell area would, without concentration. The use of concentration, therefore, allows substitution of cost-effective materials such as lenses and mirrors for the more costly semiconductor cell material.
- a single solar cell receiver under 400-Sun or more concentration can generate in excess of 14 watts of peak power.
- FIG. 1 depicts one implementation of a solar panel 10 for generating electricity from solar energy.
- the panel 10 includes a plurality of solar cell modules 20 .
- Each module 20 can comprise one or more solar cell receivers (e.g., item 12 a of FIG. 2A ) and a corresponding lens (e.g., item 204 a of FIG. 2A ) to concentrate sunlight onto the solar cell of the solar cell receiver.
- a plurality of similar panels 10 can be combined to provide a solar energy generating system of greater capacity. Where a plurality of panels 10 is provided, they are normally connected in series, but other implementations may connect the panels in parallel or series-parallel.
- FIG. 2A illustrates an implementation of a solar cell module 20 comprising an array of lenses 22 a - 22 j (four of which are not shown to provide visibility into the housing 21 of the module 20 ) and corresponding solar cell receivers 12 a - 12 j (each taking the form of item 12 of FIG. 4 ).
- a solar cell module comprises fourteen lenses and fourteen corresponding solar cell receivers.
- the array is a “7 ⁇ 2.”
- the lenses 22 a - 22 j are formed on a continuous sheet 201 of optical material (e.g., acrylic). In some implementations, regions of the sheet 201 not formed into lenses 22 a - 22 j are made partially or entirely opaque. By forming lenses 22 a - 22 j out of a continuous sheet 201 , costs can be decreased substantially. First, by producing the lenses on large sheets, production costs are decreased. Second, assembly costs are decreased because only one item (i.e., the sheet 201 of lenses) needs to be aligned with the solar cell receivers. In this implementation, sheet 201 is supported on its peripheral edges by the housing 21 and lies atop an alignment frame 206 with a plurality of frame alignment elements (e.g., holes) 205 a.
- frame alignment elements e.g., holes
- the holes 205 a may be threaded or otherwise adapted to receive a fastener.
- the sheet 201 comprises sheet alignment elements 205 b (e.g., pins, screws or other hardware) that align and couple with the frame alignment elements 205 a.
- the frame alignment elements 205 a and the sheet alignment elements 205 b are located such that by coupling the sheet alignment elements 205 b with the frame alignment elements 205 a, each solar cell receiver 12 a - 12 j is aligned with its respective lens 22 a - 22 j.
- the surface 202 comprises alignment features that ensure that each solar cell receiver 12 a - 12 j is located in a predetermined position. These features may couple with the substrate (e.g., item 9 ) of the solar cell receiver.
- the alignment elements 205 b are located generally in a center point defined by four lenses.
- an alignment element 205 b is located in a center point defined by lenses 22 f, 22 g, 22 h and 22 i.
- Another alignment element 205 is located in a center point defined by lenses 22 e, 22 f, 22 i and 22 j. This pattern of locating the alignment element 205 b in a center point defined by four lenses can continue along the entire sheet 201 .
- each lens 22 a - 22 j is a Fresnel lens.
- the corresponding solar cell receiver 12 a - 12 j is positioned at an opposite end of a housing 21 , on surface 202 .
- Each solar cell receiver 12 a - 12 j includes a corresponding solar cell 30 (see FIG. 4 ) disposed in the optical path of the corresponding lens 22 a - 22 j, i.e., such that the corresponding solar cell 30 receives light that passes through the corresponding lens 22 a - 22 j.
- additional lenses and/or mirrors are employed to place the solar cell in the optical path of the lens.
- a secondary optical element 210 b is shown that corresponds with solar cell receiver 12 b and lens 22 b.
- the secondary optical element 210 b gathers the light from lens 22 b and focuses it into the solar cell of the solar cell receiver 12 b.
- each solar cell receiver 12 a - 12 j is provided with a corresponding secondary optical element. Secondary optical elements are discussed in more detail in connection with FIG. 2B .
- any type of lens 22 a - 22 j that concentrates the incident sunlight.
- any of lenses 22 a - 22 j may take the form of a biconvex lens, a plano-convex lens, or a convex-concave lens.
- the lenses 22 a - 22 j may also comprise a multi-layer anti-reflective coating 204 a - 204 j (e.g., similar to the one applied to the solar cell 30 ).
- the distance 203 between the sheet 201 comprising lenses 22 a - 22 j and the corresponding solar cells of solar cell receivers 12 a - 12 j can be chosen, e.g., based on the focal length of the lenses 22 a - 22 j.
- the module housing 21 is arranged so that the solar cell of each respective solar cell receiver 12 a - 12 j is disposed at or about the focal point of the respective lens 22 a - 22 j.
- the focal length of each lens 22 a - 22 j is between about 25.4 cm (10 inches) and 76.2 cm (30 inches). In some implementations, the focal length of each lens 22 a - 22 j is between about 38.1 cm (15 inches) and 50.8 cm (20 inches).
- the focal length of each lens 22 a - 22 j is about 40.085 cm (17.75 inches). In some implementations, the focal length of each lens 22 a - 22 j varies, and the housing provides multiple different distances (e.g., those that are greater and/or lesser than dimension 203 ) between the sheet 201 and the surface 202 .
- the lenses 22 a - 22 j concentrate incident sunlight to 400 times normal concentration (i.e., 400 Suns) or more. In some implementations, one or more of the lenses 22 a - 22 j concentrates sunlight to about 520 times normal concentration. In some implementations, one or more of the lenses 22 a - 22 j concentrates sunlight to about 470 times normal concentration.
- conversion efficiency of solar energy into electricity increases under concentrated illumination. For example, at about 500 Suns, a single solar cell module can generate 10 watts or more of electrical power. In another example, at about 470 Suns or more, a single solar cell module can generate 14 watts or more of electrical power. The amount of electrical power a module can produce can vary depending on, for example, the combination of solar cell characteristics (e.g., size, composition) and properties of the associated optics (e.g., concentration, focus, alignment).
- the solar cell 30 of each respective solar cell receiver 12 a - 12 j is a triple-junction III-V solar cell, with each of the three sub-cells arranged in series.
- the receivers 12 a - 12 j of the solar cell modules 20 are typically electrically connected together in series.
- other applications may utilize parallel or series-parallel connection.
- receivers 12 a - 12 j within a given module 20 can be electrically connected together in series, but the modules 20 are connected to each other in parallel.
- a solar cell module includes a secondary optical element (“SOE”).
- SOE secondary optical element
- FIG. 2B An implementation of an SOE is illustrated in FIG. 2B .
- the SOE 210 is disposed inside the housing 21 of the solar cell module 20 and is generally designed to collect solar energy concentrated by an associated lens, e.g., 22 b of FIG. 2A .
- each receiver 12 a - 12 j has a respective SOE.
- the SOE 210 comprises an optical element 217 having optical inlet 219 and optical outlet 220 , a body 216 and mounting tabs 218 .
- the SOE 210 is mounted such that the optical element 217 is disposed above the solar cell 30 of the solar cell receiver 12 (e.g., 12 b of FIG. 2A ). While it may vary depending on the implementation, the SOE 210 is mounted such that the optical outlet is about 0.5 millimeters from the solar cell 30 (e.g., dimension 215 is about 0.5 millimeters).
- mounting tabs 218 couple to face 202 of the solar cell module 20 .
- the SOE 210 (including the body 216 ) can be made of metal, plastic, or glass or other materials.
- the optical element 217 has a generally square cross section that tapers from the inlet 219 to the outlet 220 .
- the inside surface 211 of the optical element reflects light downward toward the outlet 220 .
- the inside surface 211 is, in some implementations, coated with silver or another material for high reflectivity.
- the reflective coating is protected by a passivation coating such as SiO 2 to protect against oxidation, tarnish or corrosion.
- the path from the optical inlet 219 to the optical outlet 220 forms a tapered optical channel that catches solar energy from the primary lens and guides it to the solar cell.
- the SOE 210 comprises an optical element 217 having four reflective walls. In other implementations, different shapes (e.g., three-sided to form a triangular cross-section) may be employed.
- the primary lens (e.g., 22 b of FIG. 2A ) does not focus light on a spot that is of the dimensions of the solar cell 30 or a solar tracking system may not perfectly point to the sun. In these situations, some light does not reach the solar cell 30 .
- the reflective surface 211 directs light to the solar cell 30 .
- the optical element 217 can also homogenize (e.g., mix) light. In some cases, it also has some concentration effect.
- the optical inlet 219 is square-shaped and is about 49.60 mm ⁇ 49.60 mm (dimension 213 ), the optical outlet is square-shaped and is about 9.9 mm ⁇ 9.9 mm (dimension 214 ) and the height of the optical element is about 70.104 mm (dimension 214 ).
- the dimensions 214 , 213 and 214 may vary with the design of the solar cell module and the receiver.
- the dimensions of the optical outlet are approximately the same as the dimensions of the solar cell.
- the half inclination angle is 15.8 degrees.
- FIG. 3 illustrates the circuit diagram of a solar cell receiver 12 (e.g., 12 a of FIG. 2A ) of the solar cell module 20 .
- the receiver includes a triple-junction III-V compound semiconductor solar cell 30 which comprises a top cell 30 a, a middle cell 30 b and a bottom cell 30 c arranged in series.
- the solar cell 30 is positioned to receive focused solar energy from the lens (see FIGS. 2A and 2B ).
- a diode 14 is connected in parallel with the triple-junction solar cell 30 .
- the diode 14 is a semiconductor device such as a Schottky bypass diode or an epitaxially grown p-n junction.
- diode 14 is a Schottky bypass diode.
- External connection terminals 43 and 44 are provided for connecting the solar cell 30 and diode 14 to other devices, e.g., adjacent solar cell receivers.
- the solar cell 30 , the diode 14 and the terminals 43 and 44 are mounted on a board or substrate (see, e.g., item 9 of FIG. 4 ) which is made of insulating material.
- each of the triple junction solar cells 30 can be envisioned as a battery, with the cathode of each of the diodes 14 being connected to the positive terminal of the associated “battery” and the anode of each of the diodes being connected to the negative terminal of the associated “battery.”
- the associated diode 14 becomes forward-biased, and a bypass current flows only through that diode 14 (and not the solar cell 30 ).
- the non-damaged or non-shadowed solar cells continue to generate electricity from the solar energy received by those solar cells. If not for the diode 14 , substantially all of the electricity produced by the other solar cell receivers 12 will pass through the shadowed or damaged solar cell 30 , destroying it, and creating an open circuit within, e.g., the panel or array.
- FIGS. 4 , 5 and 6 illustrate one of the receivers 12 that is implemented in FIG. 2A as items 12 a - 12 j. For purposes of this implementation, it is assumed that all of the other receivers in a given array or panel are substantially the same.
- FIG. 4 illustrates one solar cell 30 and its associated diode 14 .
- the solar cell 30 is electrically connected to the diode 14 .
- the upper surface of the solar cell 30 comprises a contact area 301 that, in this implementation, occupies the perimeter of the solar cell 30 .
- the contact area 301 is smaller or larger to accommodate the desired connection type.
- the contact area 301 may touch only one, two or three sides (or portions thereof) of the solar cell 30 .
- the contact area 301 is made as small as possible to maximize the area that converts solar energy into electricity, while still allowing electrical connection. While the particular dimensions of the solar cell 30 will vary depending on the application, standard dimensions are about a 1 cm square.
- a standard set of dimensions can be about 12.58 mm ⁇ 12.58 mm overall, about 0.160 mm thick, and a total active area of about 108 mm 2 .
- the contact area 301 is about 0.98 mm wide and the aperture area is about 10 mm ⁇ 10 mm.
- the contact area 301 may be formed of a variety of conductive materials, e.g., copper, silver, and/or gold-coated silver. In this implementation, it is the n-conductivity side of the solar cell 30 that receives light, and accordingly, the contact area 301 is disposed on the n-conductivity side of the solar cell 30 .
- An anti-reflective coating 305 may be disposed on the solar cell 30 .
- the anti-reflective coating 305 may be a multi-layer antireflective coating providing low reflectance over a certain wavelength range, e.g., 0.3 to 1.8 ⁇ m.
- An example of an anti-reflective coating is a dual-layer TiO x /Al 2 O 3 dielectric stack.
- the contact 301 is coupled to a conductor trace 302 that is disposed on the board 9 .
- the contact 301 is coupled to the conductor trace 302 by a plurality (twelve in this example) of wire bonds 304 .
- the number of wire bonds 304 utilized in a particular implementation can be related, among other things, to the amount of current generated by the solar cell 30 . Generally, the greater the current, the greater number of wire bonds that are used.
- the conductor trace 302 (and hence, the solar cell 30 ) couples to terminal 11 of the diode 14 by way of an electrical connection between conductor trace 302 and conductor trace 45 .
- terminal 13 of the diode 14 is coupled to trace 46 .
- terminal 13 is coupled to the underside of the solar cell 30 . This is discussed in greater detail in connection with FIGS. 5 and 6 .
- the diode 14 is electrically coupled to the connector terminals 43 and 44 by way of traces 45 and 46 , respectively.
- the connector terminals 43 and 44 are electrically coupled to sockets 343 and 344 , respectively, mounted in the apertures 42 and 41 of connector 40 .
- Sockets 343 and 344 are shown in dotted lines because they are hidden from view by the body of the connector 40 .
- the sockets comprise an electrically conductive material (e.g., copper, silver, gold and/or a combination thereof) and provide for electrical coupling of a device to the circuit.
- the sockets correspond to anode and cathode terminals, and are designed to accept receptacle plugs 341 and 342 for connection to the adjacent receivers 312 , e.g., as described above with reference to FIG. 3 .
- Adjacent receivers 312 may take substantially the same form as receiver 12 .
- the connector 40 is in some implementations, securely attached to the board 9 and may be constructed out of an insulating material (e.g., plastic).
- the relatively large connector 40 which defines insulated apertures 41 and 42 , helps prevent a solar cell breakdown as a result of electric discharges at the terminals leading to adjacent receivers, owing to the insulated apertures providing an excellent insulation for each of the plug/socket electrical connections housed therein.
- the diode 14 is mounted above the board 9 on the terminals 11 and 13 .
- diode 14 may be a surface-mount type.
- Terminals 11 and 13 couple to anode and cathode of the diode 14 , respectively, and thus may be referred to as the anode terminal or cathode terminal of the diode 14 .
- the portions of the diode 14 aside from the terminals 11 and 13 may be referred to as the diode body (i.e., hatched region 504 ).
- diode terminal 11 is coupled electrically to a connector 501 that passes through the board 9 to couple the diode to the bottom surface of the solar cell 30 .
- connector 501 may take the form of pin that is attached to the diode 14 , and is mounted using through-hole technology.
- the connector 501 may vary depending upon how the solar cell 30 is mounted on the board 9 . If, for example, the board 9 is constructed so that bottom of the solar cell (e.g., the p-conductivity side) is exposed, the connector 501 may pass through the entire thickness of the board 9 . In some implementations, the bottom of solar cell 30 may sit on top of a surface of the board 9 .
- the connector 501 may couple to a layer of the board 9 (e.g., a layer below the top surface 505 of the board 9 ).
- the gap between bottom portion 503 the diode 14 (e.g., the surface(s) that face the board 9 ) and the board 9 is occupied by any suitable dielectric underfill material 15 , so that there is no air gap between the diode and the board.
- the underfill 15 is in contact with the bottom portion 503 of the diode 14 and the board 9 .
- the underfill 15 also may contact other areas of the diode 14 .
- suitable underfill materials include silicone.
- a suitable dielectric globtop (or conformal coating) material 16 is deposited over the diode 14 so that the diode is encapsulated.
- the coating 16 is disposed over the top surface 502 of the diode 14 (e.g., the surface(s) that face away from the board 9 ) and extends downwardly until it reaches the board 9 .
- the coating 16 thus encapsulates the diode body 504 as well as contacts 11 and 13 .
- the coating 16 contacts the top surface 502 of the diode 14 as well as contacts 11 and 13 .
- the coating 16 may contact other areas of the diode 14 .
- Suitable globtop or conformal coating materials include those sold under the Loctite® brand by the Henkel Corporation. As the dielectric material 15 and 16 has a much higher dielectric strength than air, the risk of dielectric medium breakdown is substantially eliminated.
- the underfill and globtop dielectric materials 15 and 16 prevent uncontrolled discharge of electricity, and so protect the solar cells 30 of the system.
- FIG. 6 depicts the bottom side of the receiver 12 .
- the underside 601 of the solar cell 30 is a conductive (e.g., metallized) surface.
- the underside 601 may comprise copper, silver, and/or gold coated silver and is coupled to a conductive trace 602 .
- the conductive trace 602 is coupled to connector 501 , which is coupled to terminal 11 of the diode 14 (items 11 and 14 are shown in dotted lines because they are hidden in this view).
- the conductive trace 602 may be relatively wide to carry the current generated by the solar cell 30 .
- a jumper wire is used instead of, or in combination with, the conductive trace 602 .
- the underside 601 of the solar cell 30 may rest upon a surface of the board 9 (e.g., a layer above the bottom surface 506 ). In other implementations, there may be a cutout in the board 9 that exposes the underside 601 of the solar cell 30 .
- the location of the conductive trace 602 can vary depending on how the solar cell 30 is mounted. For example, if there is a cutout in the board 9 , the conductive trace 602 may be on the bottom surface 506 of the board 9 .
- the conductive trace 602 may not be on the bottom surface of the board (e.g., it may be disposed on a layer between the top 506 and bottom 506 surfaces of the board 9 ). In such implementations, the underside 601 of the solar cell and conductive trace 602 could be hidden in this perspective.
- FIGS. 7A , 7 B and 7 C depict a second implementation of a solar cell 730 for use, for example, in a solar cell receiver such as items 12 a - 12 j of FIG. 2A or item 12 of FIG. 4 .
- Solar cell 730 is a multijunction cell having n-on-p polarity and is composed of InGaP/(In)GaAs III-V compounds on a Ge substrate.
- the solar cell 730 also includes an anti-reflective coating comprising a dual-layer TiO x /Al 2 O 3 dielectric stack, whose spectral reflectivity characteristics are designed to minimize reflection at the coverglass-interconnect-cell (CIC) or solar cell assembly (SCA) level, as well as, maximizing the end-of-life (EOL) performance of the cells.
- FIGS. 7A and 7B are from the perspective of the n-polarity side.
- cell 730 utilizes two terminals 703 and 704 (“bus bars”) rather than the perimeter contact 301 of cell 30 .
- the terminals 703 and 704 are surrounded by a passivated frame 705 (visible in FIG. 7B , a close-up of region 701 ).
- the region occupied by the contacts 703 and 704 is not part of the active area 702 (e.g., a region capable of converting solar energy to electricity).
- One advantage of this implementation is that a large percentage of the overall surface area is the active area 702 because the contacts 703 and 704 occupy just two sides of the cell 730 .
- the overall dimensions of the cell 730 are about 11.18 mm (dimension 710 ) by 10.075 mm (dimension 714 ).
- the cell 730 is about 0.185 mm thick (dimension 718 ).
- the active area 702 is about 10 mm (dimension 712 ) by 10.075 mm (dimension 714 ).
- the terminals 703 and 704 are about 9.905 mm wide (dimension 715 ) by 0.505 mm high (dimension 717 ), and are located about 0.085 mm (dimensions 713 and 719 ) from the edges of the cell 730 . Accordingly, the distance from the outer edge of terminal 703 to the outer edge of terminal 704 is about 11.01 mm (dimension 711 ).
- the passivated frame 705 around the terminals 703 and 704 is about 0.01 mm thick (dimension 720 ).
- some implementations employ a thin border (e.g., 0.035 mm, dimension 716 ) around the entire cell 730 where there are substantially no features.
- the bottom of cell 730 (i.e., the p-polarity side) is substantially similar to that of cell 30 illustrated in FIG. 6 .
- FIG. 8 illustrates an alternative implementation of a solar cell receiver 812 which comprises solar cell 830 and its associated diode 814 .
- Solar cell receiver 812 can be used in applications in substantially the same manner as receiver 12 of FIG. 4 .
- the solar cell 830 is electrically connected to the diode 814 .
- the upper surface of the solar cell 830 comprises a contact area 801 that, in this implementation, occupies two edges of the solar cell 830 .
- the contact area 801 is made as small as possible to maximize the area that converts solar energy into electricity, while still allowing electrical connection. While the particular dimensions of the solar cell 830 will vary depending on the application, standard dimensions are about a 1 cm square.
- a standard set of dimensions can be about 12.58 mm ⁇ 12.58 mm overall, about 0.160 mm thick, and a total active area of about 108 mm 2 .
- the contact area 801 is about 0.98 mm wide and the aperture area is about 10 mm ⁇ 10 mm.
- the contact area 801 may be formed of a variety of conductive materials, e.g., copper, silver, and/or gold-coated silver. In this implementation, it is the n-conductivity side of the solar cell 830 that receives light, and accordingly, the contact area 801 is disposed on the n-conductivity side of the solar cell 830 .
- An anti-reflective coating may be disposed on the n-conductivity side (or any side that receives solar energy) of the solar cell 830 .
- the contact 801 is coupled to a conductor trace 802 that is disposed on the board 809 .
- the contact 801 is coupled to the conductor trace 802 by a plurality of wire bonds 804 .
- the number of wire bonds 804 utilized in a particular implementation can be related, among other things, to the amount of current generated by the solar cell 830 . Generally, the greater the current, the greater number of wire bonds that are used.
- the conductor trace 802 (and hence, the solar cell 830 ) couples to terminal 811 of the diode 814 by way of an electrical connection between conductor trace 802 and conductor trace 845 .
- terminal 813 of the diode 814 is coupled to trace 846 .
- terminal 813 is coupled to the underside of the solar cell 830 . An example of this type of connection is discussed in connection with FIGS. 5 and 6 .
- the diode 814 is electrically coupled to the sockets 843 and 844 by way of traces 845 and 846 , respectively.
- the sockets 843 and 844 are electrically insulated from each other by the connector 840 .
- the connector 840 includes apertures for each socket. The apertures are electrically insulated from each other. Sockets 843 and 844 are shown in dotted lines because they are hidden from view by the body of the connector 40 .
- the sockets comprise an electrically conductive material (e.g., copper, silver, gold and/or a combination thereof) and provide for electrical coupling of a device to the circuit.
- the sockets correspond to anode and cathode terminals, and are designed to accept receptacle plugs (e.g., 341 and 342 of FIG. 4 ) for connection to the adjacent receivers, e.g., as described with reference to FIG. 3 .
- the connector 840 is in some implementations, securely attached to the board 809 and may be constructed out of an insulating material (e.g., plastic).
- the relatively large connector 840 helps prevent a solar cell breakdown as a result of electric discharges at the terminals leading to adjacent receivers, owing to the insulated apertures providing an excellent insulation for each of the plug/socket electrical connections housed therein.
- the diode 814 is coated with a globtop dielectric coating 816 . Also, a dielectric underfill is placed beneath the diode 814 between the terminals 811 and 813 . The use of these materials is discussed in connection with FIG. 5 (e.g., items 15 and 16 ).
- the use of the underfill and/or globtop e.g., conformal coating
- the underfill and/or globtop can result in additional, unexpected, advantages.
- underfill and/or globtop can substantially improve the ability of a receiver to manage heat dissipation.
- the underfill and globtop dielectric materials e.g., 15 and 16
- the underfill and globtop dielectric materials have a higher thermal conductivity than air. Consequently, they improve heat dissipation from the components of the system to the surrounding ambient atmosphere by increasing the cross-section of the thermal path.
- the underfill and globtop dielectric materials e.g., 15 and 16
- the underfill 15 and globtop 16 substantially improve the heat dissipation of the diode 14 .
- the diode 14 when bypassing the solar cell 30 , the diode 14 may be carrying several thousand (e.g., 10,000) watts of electrical power. Because diodes are not perfectly efficient electrical conductors, some of that power is dissipated as thermal energy. Excessive thermal energy can destroy the diode, and at a minimum, reduce its service life. As a result, receivers that employ underfill and/or globtop are likely to have increased service life, especially as power levels increase. Moreover, the underfill and/or globtop is a much more cost effective, efficient and lighter solution than many other methods (e.g., passive cooling using metal heat sinks or active cooling) for improving heat management. Moreover, those other methods do not solve the problem of uncontrolled discharge.
- other methods e.g., passive cooling using metal heat sinks or active cooling
- the underfill and/or globtop materials can also protect against short circuits resulting from contaminants.
- the conductor traces e.g., items 45 and 46
- the conductor traces are separated by no more than approximately 1 mm (0.394 inches). When traces are this close to each other, many contaminants, such as a droplet of water, are sufficiently large to contact two adjacent conductor traces.
- the diode 14 is itself relatively small, it is possible for one or more water droplets to bridge terminals 11 and 13 . Since solar receivers (e.g., 12 ) often are used outdoors, they are exposed to moisture, for example, from condensation and/or rain.
- the use of the underfill and/or globtop prevents moisture from condensing on the terminals of the diode 14 or on the conductor traces 45 and 46 , thereby reducing the probability of short circuits.
- the underfill and/or dielectric globtop (or conformal coating) materials 15 and 16 also prevent foreign materials falling onto the terminals of the diodes 14 , onto the conductor traces 45 and 46 and onto any electrical traces on the board 9 , thereby further reducing the probability of short circuits during operation.
- underfill and/or globtop dielectric materials add mechanical integrity to the interfaces between the diodes and the boards to which they are attached. As a result, during transport, installation and handling, the likelihood of the diode becoming detached (or otherwise electrically de-coupled) is reduced.
- Testing implementations of solar cell receivers (e.g., item 12 ) at different solar concentrations resulted in the following data.
- the testing at 470 Suns and 1150 Suns involved utilization of the solar cell receiver 12 as part of a solar cell module assembly (e.g., item 20 ).
- the dielectric material could be applied not only to the diodes, but also to all terminals, leads, and conductor traces on the panel.
- the solar cell module housings can be made adjustable, for example, (1) to accommodate lenses having different focal lengths or (2) to increase or decrease concentration (i.e., Suns) by moving the solar cell away from or toward the focal point.
- multiple lenses may be arrayed, for example, to focus incoming light precisely onto the solar cell.
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Abstract
Description
- This application is a continuation of U.S. patent application Ser. No. 12/069,642 filed Feb. 11, 2008, the entire contents of which are hereby incorporated herein by reference.
- The disclosure of this application is related to co-pending U.S. application Ser. No. 11/830,576, filed on Jul. 30, 2007; U.S. application Ser. No. 11/830,636, filed on Jul. 30, 2007 and U.S. application Ser. No. 11/849,033, filed on Aug. 31, 2007.
- This disclosure relates to a solar cell receiver for a concentrated photovoltaic system design for a III-V compound semiconductor multijunction solar cell.
- Satisfying the world's growing demand for energy is one of the most significant challenges facing society. At present, about 85% of the energy produced in the United States comes from fossil fuels. Given that the supply of such fuels is on the decline, their prices continue to rise, and the resultant greenhouse gases may contribute to global warming, there is a need to develop new technologies that are economically feasible and environmentally friendly.
- Solar energy is one technology for power generation that is clean, quiet and renewable. It is also plentiful: with an average of roughly 125,000 terawatts of solar energy reaching the planet at any given time, solar technology can potentially generate a significant amount of energy.
- Solar cells are used to convert solar or radiant energy into electricity. Typically, a plurality of solar cells are disposed in an array or panel, and a solar energy system typically includes a plurality of such panels. The solar cells in each panel are usually connected in series, and the panels in a given system are also connected in series, with
- Historically, solar power (both in space and terrestrially) has been predominantly provided by silicon solar cells. In the past several years, however, high-volume manufacturing of high-efficiency III-V multijunction solar cells has enabled the consideration of this alternative technology for terrestrial power generation. Compared to Si, III-V multijunction cells are generally more radiation resistant and have greater energy conversion efficiencies, but they tend to cost more. Some current III-V multijunction cells have energy efficiencies that exceed 27%, whereas silicon technologies generally reach only about 17% efficiency. Under concentration, some current III-V multijunction cells have energy efficiencies that exceed 37%. When the need for very high power or smaller solar arrays are paramount in a spacecraft or other solar energy system, multijunction cells are often used instead of, or in hybrid combinations with, Si-based cells to reduce the array size.
- Generally speaking, the multijunction cells are of n-on-p polarity and are composed of InGaP/(In)GaAs/Ge compounds. III-V compound semiconductor multijunction solar cell layers can be grown via metal-organic chemical vapor deposition (MOCVD) on Ge substrates. The use of the Ge substrate permits a junction to be formed between n- and p-Ge. The solar cell structures can be grown on 100-mm diameter (4 inch) Ge substrates with an average mass density of about 86 mg/cm2. In some processes, the epitaxial layer uniformity across a platter that holds 12 or 13 Ge substrates during the MOCVD growth process is better than 99.5%. Each wafer typically yields two large-area solar cells. The cell areas that are processed for production typically range from 26.6 to 32.4 cm2. The epi-wafers can be processed into complete devices through automated robotic photolithography, metallization, chemical cleaning and etching, antireflection (AR) coating, dicing, and testing processes. The n- & p-contact metallization is typically comprised of predominately Ag with a thin Au cap layer to protect the Ag from oxidation. The AR coating is a dual-layer TiOx/Al2O3 dielectric stack, whose spectral reflectivity characteristics are designed to minimize reflection at the coverglass-interconnect-cell (CIC) or solar cell assembly (SCA) level, as well as, maximizing the end-of-life (EOL) performance of the cells.
- In some multijunction cells, the middle cell is an InGaAs cell as opposed to a GaAs cell. The indium concentration may be in the range of about 1.5% for the InGaAs middle cell. In some implementations, such an arrangement exhibits increased efficiency. The InGaAs layers are substantially perfectly lattice-matched to the Ge substrate.
- Regardless of the type of cell used, a known problem with solar energy systems is that individual solar cells can become damaged or shadowed by an obstruction. For example, damage can occur as a result of exposure of a solar cell to harsh environmental conditions. The current-carrying capacity of a panel having one or more damaged or shadowed solar cells is reduced, and the output from other panels in series with that panel reverse biases the damaged or shadowed cells. The voltage across the damaged or shadowed cells thus increases in a reverse polarity until the full output voltage of all of the panels in the series is applied to the damaged or shadowed cells in the panel concerned. This causes the damaged or shadowed cells to breakdown.
- As a solar cell system for terrestrial applications has thousands of solar cells, its voltage output is normally in the range of hundreds of volts, and its current output is in the range of tens of amperes. At these output power levels, if the solar cell terminals are not protected, uncontrollable electric discharge in the form of sparks tends to occur, and this can cause damage to the solar cells and to the entire system.
- Another disadvantage of known solar cell receivers is that, owing to the need for such a receiver to generate 10 watts of power at 1000 volts for an extended period of up to, or exceeding, twenty years, there is a danger of sparking at various points on the receiver or at the electrical terminals which connect one receiver of a solar cell system to adjacent receivers.
- In an aspect of the invention, a solar cell module comprises a solar cell receiver having a multijunction III-V compound semiconductor solar cell, a secondary optical element and a lens to concentrate incident light onto the solar cell.
- The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features and advantages will be apparent from the description and drawings, and from the claims.
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FIG. 1 is a perspective view of an implementation of a solar panel including apparatus for generating electricity from solar energy. -
FIG. 2A is a perspective view of an implementation of a solar cell module. -
FIG. 2B is a perspective view of an implementation of a secondary optical element. -
FIG. 3 is a circuit diagram of the solar cell receiver ofFIG. 4 . -
FIG. 4 is a perspective view of an implementation of a solar cell receiver, which forms part of the solar cell module ofFIG. 2A . -
FIG. 5 is a cross-section taken on line A-A ofFIG. 4 . -
FIG. 6 is a view of the bottom of an implementation of a solar cell receiver. -
FIGS. 7A , 7B and 7C depict an alternative implementation of a solar cell. -
FIG. 8 depicts an alternative implementation of a solar cell receiver. - The following is a description of preferred implementations, as well as some alternative implementations, of a solar cell receiver having an insulated bypass diode.
- I. Overview
- Solar cell receivers convert solar energy into electricity. To accomplish this result, solar cell receivers generally comprise one or more solar cells. A solar cell may be made from, e.g., silicon (including amorphous, nanocrystalline, or protocrystalline), cadmium telluride, CIGS (copper indium gallium diselenide), CIS (chalcopyrite films of copper indium selenide (CuInSe2)), gallium arsenide (e.g., GaAs multijunctions), light absorbing dyes (e.g., ruthenium metalorganic dye), or organic semiconductors (e.g., polyphenylene vinylene, copper phthalocyanine or carbon fullerenes). In various implementations described herein, a triple-junction III-V compound semiconductor solar cell is employed, but other types of solar cells could be used depending upon the application. Solar cell receivers often contain additional components, e.g., connectors for coupling to an output device or other solar cell receivers.
- For some applications, a solar cell receiver may be implemented as part of a solar cell module. A solar cell module may include a solar cell receiver and a lens coupled to the solar cell. The lens is used to focus received light onto the solar cell. As a result of the lens, a greater concentration of solar energy can be received by the solar cell. In some implementations, the lens is adapted to concentrate solar energy by a factor of 400 or more. For example, under 500-Sun concentration, 1 cm2 of solar cell area produces the same amount of electrical power as 500 cm2 of solar cell area would, without concentration. The use of concentration, therefore, allows substitution of cost-effective materials such as lenses and mirrors for the more costly semiconductor cell material. In some implementations, a single solar cell receiver under 400-Sun or more concentration can generate in excess of 14 watts of peak power.
- Since a single solar cell module may not produce sufficient electricity for a given application, two or more solar cell modules may be grouped together into an array. These arrays are sometimes referred to as “panels” or “solar panels.”
- II. Implementations of a Solar Panel
-
FIG. 1 depicts one implementation of asolar panel 10 for generating electricity from solar energy. Thepanel 10 includes a plurality ofsolar cell modules 20. In this illustration, twenty-foursolar cell modules 20 are shown. Eachmodule 20 can comprise one or more solar cell receivers (e.g., item 12 a ofFIG. 2A ) and a corresponding lens (e.g.,item 204 a ofFIG. 2A ) to concentrate sunlight onto the solar cell of the solar cell receiver. A plurality ofsimilar panels 10 can be combined to provide a solar energy generating system of greater capacity. Where a plurality ofpanels 10 is provided, they are normally connected in series, but other implementations may connect the panels in parallel or series-parallel. - III. Implementations of a Solar Cell Module
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FIG. 2A illustrates an implementation of asolar cell module 20 comprising an array of lenses 22 a-22 j (four of which are not shown to provide visibility into thehousing 21 of the module 20) and correspondingsolar cell receivers 12 a-12 j (each taking the form ofitem 12 ofFIG. 4 ). In some implementations, a solar cell module comprises fourteen lenses and fourteen corresponding solar cell receivers. In the illustrated implementation, the array is a “7×2.” - The lenses 22 a-22 j are formed on a continuous sheet 201 of optical material (e.g., acrylic). In some implementations, regions of the sheet 201 not formed into lenses 22 a-22 j are made partially or entirely opaque. By forming lenses 22 a-22 j out of a continuous sheet 201, costs can be decreased substantially. First, by producing the lenses on large sheets, production costs are decreased. Second, assembly costs are decreased because only one item (i.e., the sheet 201 of lenses) needs to be aligned with the solar cell receivers. In this implementation, sheet 201 is supported on its peripheral edges by the
housing 21 and lies atop analignment frame 206 with a plurality of frame alignment elements (e.g., holes) 205 a. The holes 205 a may be threaded or otherwise adapted to receive a fastener. The sheet 201 comprisessheet alignment elements 205 b (e.g., pins, screws or other hardware) that align and couple with the frame alignment elements 205 a. The frame alignment elements 205 a and thesheet alignment elements 205 b are located such that by coupling thesheet alignment elements 205 b with the frame alignment elements 205 a, eachsolar cell receiver 12 a-12 j is aligned with its respective lens 22 a-22 j. In some implementations, thesurface 202 comprises alignment features that ensure that eachsolar cell receiver 12 a-12 j is located in a predetermined position. These features may couple with the substrate (e.g., item 9) of the solar cell receiver. - The
alignment elements 205 b (e.g., a pin) are located generally in a center point defined by four lenses. For example, analignment element 205 b is located in a center point defined bylenses lenses alignment element 205 b in a center point defined by four lenses can continue along the entire sheet 201. - In some implementations, each lens 22 a-22 j is a Fresnel lens. The corresponding
solar cell receiver 12 a-12 j is positioned at an opposite end of ahousing 21, onsurface 202. Eachsolar cell receiver 12 a-12 j includes a corresponding solar cell 30 (seeFIG. 4 ) disposed in the optical path of the corresponding lens 22 a-22 j, i.e., such that the correspondingsolar cell 30 receives light that passes through the corresponding lens 22 a-22 j. In some implementations, additional lenses and/or mirrors are employed to place the solar cell in the optical path of the lens. For example, a secondaryoptical element 210 b is shown that corresponds with solar cell receiver 12 b andlens 22 b. The secondaryoptical element 210 b gathers the light fromlens 22 b and focuses it into the solar cell of the solar cell receiver 12 b. In some implementations, eachsolar cell receiver 12 a-12 j is provided with a corresponding secondary optical element. Secondary optical elements are discussed in more detail in connection withFIG. 2B . - While some Fresnel lenses can concentrate more sunlight than some convex lenses, implementations may use any type of lens 22 a-22 j that concentrates the incident sunlight. For example, any of lenses 22 a-22 j may take the form of a biconvex lens, a plano-convex lens, or a convex-concave lens. The lenses 22 a-22 j may also comprise a multi-layer anti-reflective coating 204 a-204 j (e.g., similar to the one applied to the solar cell 30).
- The
distance 203 between the sheet 201 comprising lenses 22 a-22 j and the corresponding solar cells ofsolar cell receivers 12 a-12 j can be chosen, e.g., based on the focal length of the lenses 22 a-22 j. In some implementations themodule housing 21 is arranged so that the solar cell of each respectivesolar cell receiver 12 a-12 j is disposed at or about the focal point of the respective lens 22 a-22 j. In some implementations, the focal length of each lens 22 a-22 j is between about 25.4 cm (10 inches) and 76.2 cm (30 inches). In some implementations, the focal length of each lens 22 a-22 j is between about 38.1 cm (15 inches) and 50.8 cm (20 inches). In some implementations, the focal length of each lens 22 a-22 j is about 40.085 cm (17.75 inches). In some implementations, the focal length of each lens 22 a-22 j varies, and the housing provides multiple different distances (e.g., those that are greater and/or lesser than dimension 203) between the sheet 201 and thesurface 202. - Some implementations of the lenses 22 a-22 j concentrate incident sunlight to 400 times normal concentration (i.e., 400 Suns) or more. In some implementations, one or more of the lenses 22 a-22 j concentrates sunlight to about 520 times normal concentration. In some implementations, one or more of the lenses 22 a-22 j concentrates sunlight to about 470 times normal concentration. Generally speaking, conversion efficiency of solar energy into electricity increases under concentrated illumination. For example, at about 500 Suns, a single solar cell module can generate 10 watts or more of electrical power. In another example, at about 470 Suns or more, a single solar cell module can generate 14 watts or more of electrical power. The amount of electrical power a module can produce can vary depending on, for example, the combination of solar cell characteristics (e.g., size, composition) and properties of the associated optics (e.g., concentration, focus, alignment).
- In some implementations, the
solar cell 30 of each respectivesolar cell receiver 12 a-12 j is a triple-junction III-V solar cell, with each of the three sub-cells arranged in series. In applications where multiplesolar cell modules 20 are employed, thereceivers 12 a-12 j of thesolar cell modules 20 are typically electrically connected together in series. However, other applications may utilize parallel or series-parallel connection. For example,receivers 12 a-12 j within a givenmodule 20 can be electrically connected together in series, but themodules 20 are connected to each other in parallel. - Some implementations of a solar cell module include a secondary optical element (“SOE”). An implementation of an SOE is illustrated in
FIG. 2B . TheSOE 210 is disposed inside thehousing 21 of thesolar cell module 20 and is generally designed to collect solar energy concentrated by an associated lens, e.g., 22 b ofFIG. 2A . In some implementations, eachreceiver 12 a-12 j has a respective SOE. - The
SOE 210 comprises anoptical element 217 havingoptical inlet 219 andoptical outlet 220, abody 216 and mountingtabs 218. TheSOE 210 is mounted such that theoptical element 217 is disposed above thesolar cell 30 of the solar cell receiver 12 (e.g., 12 b ofFIG. 2A ). While it may vary depending on the implementation, theSOE 210 is mounted such that the optical outlet is about 0.5 millimeters from the solar cell 30 (e.g.,dimension 215 is about 0.5 millimeters). In some implementations, mountingtabs 218 couple to face 202 of thesolar cell module 20. The SOE 210 (including the body 216) can be made of metal, plastic, or glass or other materials. - In some implementations, the
optical element 217 has a generally square cross section that tapers from theinlet 219 to theoutlet 220. Theinside surface 211 of the optical element reflects light downward toward theoutlet 220. Theinside surface 211 is, in some implementations, coated with silver or another material for high reflectivity. In some cases, the reflective coating is protected by a passivation coating such as SiO2 to protect against oxidation, tarnish or corrosion. The path from theoptical inlet 219 to theoptical outlet 220 forms a tapered optical channel that catches solar energy from the primary lens and guides it to the solar cell. As shown in this implementation, theSOE 210 comprises anoptical element 217 having four reflective walls. In other implementations, different shapes (e.g., three-sided to form a triangular cross-section) may be employed. - In some cases, the primary lens (e.g., 22 b of
FIG. 2A ) does not focus light on a spot that is of the dimensions of thesolar cell 30 or a solar tracking system may not perfectly point to the sun. In these situations, some light does not reach thesolar cell 30. Thereflective surface 211 directs light to thesolar cell 30. Theoptical element 217 can also homogenize (e.g., mix) light. In some cases, it also has some concentration effect. - In some implementations, the
optical inlet 219 is square-shaped and is about 49.60 mm×49.60 mm (dimension 213), the optical outlet is square-shaped and is about 9.9 mm×9.9 mm (dimension 214) and the height of the optical element is about 70.104 mm (dimension 214). Thedimensions - IV. Implementations of a Solar Cell Receiver
-
FIG. 3 illustrates the circuit diagram of a solar cell receiver 12 (e.g., 12 a ofFIG. 2A ) of thesolar cell module 20. The receiver includes a triple-junction III-V compound semiconductorsolar cell 30 which comprises atop cell 30 a, amiddle cell 30 b and abottom cell 30 c arranged in series. When implemented in a solar cell module, thesolar cell 30 is positioned to receive focused solar energy from the lens (seeFIGS. 2A and 2B ). - A
diode 14 is connected in parallel with the triple-junctionsolar cell 30. In some implementations, thediode 14 is a semiconductor device such as a Schottky bypass diode or an epitaxially grown p-n junction. For purposes of illustration,diode 14 is a Schottky bypass diode.External connection terminals solar cell 30 anddiode 14 to other devices, e.g., adjacent solar cell receivers. In some implementations, thesolar cell 30, thediode 14 and theterminals item 9 ofFIG. 4 ) which is made of insulating material. - The functionality of the
diode 14 can be appreciated by considering multiplesolar cell receivers 12 connected in series. Each of the triple junctionsolar cells 30 can be envisioned as a battery, with the cathode of each of thediodes 14 being connected to the positive terminal of the associated “battery” and the anode of each of the diodes being connected to the negative terminal of the associated “battery.” When one of the serially-connectedsolar cells 30 becomes damaged or shadowed, its voltage output is reduced or eliminated (e.g., to below a threshold voltage associated with the diode 14). Therefore, the associateddiode 14 becomes forward-biased, and a bypass current flows only through that diode 14 (and not the solar cell 30). In this manner, the non-damaged or non-shadowed solar cells continue to generate electricity from the solar energy received by those solar cells. If not for thediode 14, substantially all of the electricity produced by the othersolar cell receivers 12 will pass through the shadowed or damagedsolar cell 30, destroying it, and creating an open circuit within, e.g., the panel or array. -
FIGS. 4 , 5 and 6 illustrate one of thereceivers 12 that is implemented inFIG. 2A asitems 12 a-12 j. For purposes of this implementation, it is assumed that all of the other receivers in a given array or panel are substantially the same. -
FIG. 4 illustrates onesolar cell 30 and its associateddiode 14. Thesolar cell 30 is electrically connected to thediode 14. The upper surface of thesolar cell 30 comprises acontact area 301 that, in this implementation, occupies the perimeter of thesolar cell 30. In some implementations, thecontact area 301 is smaller or larger to accommodate the desired connection type. For example, thecontact area 301 may touch only one, two or three sides (or portions thereof) of thesolar cell 30. In some implementations, thecontact area 301 is made as small as possible to maximize the area that converts solar energy into electricity, while still allowing electrical connection. While the particular dimensions of thesolar cell 30 will vary depending on the application, standard dimensions are about a 1 cm square. For example, a standard set of dimensions can be about 12.58 mm×12.58 mm overall, about 0.160 mm thick, and a total active area of about 108 mm2. For example, in asolar cell 30 that is approximately 12.58 mm×12.58 mm, thecontact area 301 is about 0.98 mm wide and the aperture area is about 10 mm×10 mm. Thecontact area 301 may be formed of a variety of conductive materials, e.g., copper, silver, and/or gold-coated silver. In this implementation, it is the n-conductivity side of thesolar cell 30 that receives light, and accordingly, thecontact area 301 is disposed on the n-conductivity side of thesolar cell 30. - An
anti-reflective coating 305 may be disposed on thesolar cell 30. Theanti-reflective coating 305 may be a multi-layer antireflective coating providing low reflectance over a certain wavelength range, e.g., 0.3 to 1.8 μm. An example of an anti-reflective coating is a dual-layer TiOx/Al2O3 dielectric stack. - The
contact 301 is coupled to aconductor trace 302 that is disposed on theboard 9. In this implementation, thecontact 301 is coupled to theconductor trace 302 by a plurality (twelve in this example) ofwire bonds 304. The number ofwire bonds 304 utilized in a particular implementation can be related, among other things, to the amount of current generated by thesolar cell 30. Generally, the greater the current, the greater number of wire bonds that are used. - The conductor trace 302 (and hence, the solar cell 30) couples to
terminal 11 of thediode 14 by way of an electrical connection betweenconductor trace 302 andconductor trace 45. - The
other terminal 13 of thediode 14 is coupled to trace 46. To complete the parallel connection between thesolar cell 30 and thediode 14,terminal 13 is coupled to the underside of thesolar cell 30. This is discussed in greater detail in connection withFIGS. 5 and 6 . - The
diode 14 is electrically coupled to theconnector terminals traces connector terminals sockets apertures connector 40.Sockets connector 40. The sockets comprise an electrically conductive material (e.g., copper, silver, gold and/or a combination thereof) and provide for electrical coupling of a device to the circuit. In some implementations, the sockets correspond to anode and cathode terminals, and are designed to accept receptacle plugs 341 and 342 for connection to theadjacent receivers 312, e.g., as described above with reference toFIG. 3 .Adjacent receivers 312 may take substantially the same form asreceiver 12. Theconnector 40, is in some implementations, securely attached to theboard 9 and may be constructed out of an insulating material (e.g., plastic). - The relatively
large connector 40, which defines insulatedapertures - As shown in
FIG. 5 , thediode 14 is mounted above theboard 9 on theterminals diode 14 may be a surface-mount type.Terminals diode 14, respectively, and thus may be referred to as the anode terminal or cathode terminal of thediode 14. The portions of thediode 14 aside from theterminals - In this implementation,
diode terminal 11 is coupled electrically to aconnector 501 that passes through theboard 9 to couple the diode to the bottom surface of thesolar cell 30. In some implementations,connector 501 may take the form of pin that is attached to thediode 14, and is mounted using through-hole technology. Theconnector 501 may vary depending upon how thesolar cell 30 is mounted on theboard 9. If, for example, theboard 9 is constructed so that bottom of the solar cell (e.g., the p-conductivity side) is exposed, theconnector 501 may pass through the entire thickness of theboard 9. In some implementations, the bottom ofsolar cell 30 may sit on top of a surface of theboard 9. For such implementations, theconnector 501 may couple to a layer of the board 9 (e.g., a layer below thetop surface 505 of the board 9). - The gap between
bottom portion 503 the diode 14 (e.g., the surface(s) that face the board 9) and theboard 9 is occupied by any suitabledielectric underfill material 15, so that there is no air gap between the diode and the board. In some implementations, there is no air gap between thecontacts underfill 15 occupies substantially all of the space between thebottom portion 503 of thediode 14 and theboard 9. In that case, theunderfill 15 is in contact with thebottom portion 503 of thediode 14 and theboard 9. Theunderfill 15 also may contact other areas of thediode 14. Examples of suitable underfill materials include silicone. Similarly, a suitable dielectric globtop (or conformal coating)material 16 is deposited over thediode 14 so that the diode is encapsulated. Thecoating 16 is disposed over thetop surface 502 of the diode 14 (e.g., the surface(s) that face away from the board 9) and extends downwardly until it reaches theboard 9. Thecoating 16 thus encapsulates thediode body 504 as well ascontacts coating 16 contacts thetop surface 502 of thediode 14 as well ascontacts coating 16 may contact other areas of thediode 14. Suitable globtop or conformal coating materials include those sold under the Loctite® brand by the Henkel Corporation. As thedielectric material dielectric materials solar cells 30 of the system. -
FIG. 6 depicts the bottom side of thereceiver 12. Theunderside 601 of thesolar cell 30 is a conductive (e.g., metallized) surface. Theunderside 601 may comprise copper, silver, and/or gold coated silver and is coupled to aconductive trace 602. Theconductive trace 602 is coupled toconnector 501, which is coupled toterminal 11 of the diode 14 (items conductive trace 602 may be relatively wide to carry the current generated by thesolar cell 30. In some embodiments, a jumper wire is used instead of, or in combination with, theconductive trace 602. - Depending upon the implementation, the
underside 601 of thesolar cell 30 may rest upon a surface of the board 9 (e.g., a layer above the bottom surface 506). In other implementations, there may be a cutout in theboard 9 that exposes theunderside 601 of thesolar cell 30. The location of theconductive trace 602 can vary depending on how thesolar cell 30 is mounted. For example, if there is a cutout in theboard 9, theconductive trace 602 may be on thebottom surface 506 of theboard 9. If thesolar cell 30 rests upon a layer of the board above thebottom surface 506, theconductive trace 602 may not be on the bottom surface of the board (e.g., it may be disposed on a layer between the top 506 and bottom 506 surfaces of the board 9). In such implementations, theunderside 601 of the solar cell andconductive trace 602 could be hidden in this perspective. - V. Second Implementation of a Solar Cell
-
FIGS. 7A , 7B and 7C depict a second implementation of asolar cell 730 for use, for example, in a solar cell receiver such asitems 12 a-12 j ofFIG. 2A oritem 12 ofFIG. 4 .Solar cell 730 is a multijunction cell having n-on-p polarity and is composed of InGaP/(In)GaAs III-V compounds on a Ge substrate. Thesolar cell 730 also includes an anti-reflective coating comprising a dual-layer TiOx/Al2O3 dielectric stack, whose spectral reflectivity characteristics are designed to minimize reflection at the coverglass-interconnect-cell (CIC) or solar cell assembly (SCA) level, as well as, maximizing the end-of-life (EOL) performance of the cells.FIGS. 7A and 7B are from the perspective of the n-polarity side. - One difference between this
solar cell 730 and thesolar cell 30 ofFIG. 4 is thatcell 730 utilizes twoterminals 703 and 704 (“bus bars”) rather than theperimeter contact 301 ofcell 30. Theterminals FIG. 7B , a close-up of region 701). The region occupied by thecontacts active area 702 because thecontacts cell 730. - The overall dimensions of the
cell 730 are about 11.18 mm (dimension 710) by 10.075 mm (dimension 714). Thecell 730 is about 0.185 mm thick (dimension 718). Theactive area 702 is about 10 mm (dimension 712) by 10.075 mm (dimension 714). - The
terminals dimensions 713 and 719) from the edges of thecell 730. Accordingly, the distance from the outer edge ofterminal 703 to the outer edge ofterminal 704 is about 11.01 mm (dimension 711). The passivatedframe 705 around theterminals entire cell 730 where there are substantially no features. - The bottom of cell 730 (i.e., the p-polarity side) is substantially similar to that of
cell 30 illustrated inFIG. 6 . - VI. Alternative Implementation of a Solar Cell Receiver
-
FIG. 8 illustrates an alternative implementation of asolar cell receiver 812 which comprisessolar cell 830 and its associateddiode 814.Solar cell receiver 812 can be used in applications in substantially the same manner asreceiver 12 ofFIG. 4 . Thesolar cell 830 is electrically connected to thediode 814. The upper surface of thesolar cell 830 comprises acontact area 801 that, in this implementation, occupies two edges of thesolar cell 830. In some implementations, thecontact area 801 is made as small as possible to maximize the area that converts solar energy into electricity, while still allowing electrical connection. While the particular dimensions of thesolar cell 830 will vary depending on the application, standard dimensions are about a 1 cm square. For example, a standard set of dimensions can be about 12.58 mm×12.58 mm overall, about 0.160 mm thick, and a total active area of about 108 mm2. For example, in asolar cell 830 that is approximately 12.58 mm×12.58 mm, thecontact area 801 is about 0.98 mm wide and the aperture area is about 10 mm×10 mm. Thecontact area 801 may be formed of a variety of conductive materials, e.g., copper, silver, and/or gold-coated silver. In this implementation, it is the n-conductivity side of thesolar cell 830 that receives light, and accordingly, thecontact area 801 is disposed on the n-conductivity side of thesolar cell 830. - An anti-reflective coating may be disposed on the n-conductivity side (or any side that receives solar energy) of the
solar cell 830. - The
contact 801 is coupled to aconductor trace 802 that is disposed on theboard 809. In this implementation, thecontact 801 is coupled to theconductor trace 802 by a plurality ofwire bonds 804. The number ofwire bonds 804 utilized in a particular implementation can be related, among other things, to the amount of current generated by thesolar cell 830. Generally, the greater the current, the greater number of wire bonds that are used. - The conductor trace 802 (and hence, the solar cell 830) couples to
terminal 811 of thediode 814 by way of an electrical connection betweenconductor trace 802 andconductor trace 845. - The
other terminal 813 of thediode 814 is coupled to trace 846. To complete the parallel connection between thesolar cell 830 and thediode 814, terminal 813 is coupled to the underside of thesolar cell 830. An example of this type of connection is discussed in connection withFIGS. 5 and 6 . - The
diode 814 is electrically coupled to thesockets traces sockets connector 840. Theconnector 840 includes apertures for each socket. The apertures are electrically insulated from each other.Sockets connector 40. The sockets comprise an electrically conductive material (e.g., copper, silver, gold and/or a combination thereof) and provide for electrical coupling of a device to the circuit. In some implementations, the sockets correspond to anode and cathode terminals, and are designed to accept receptacle plugs (e.g., 341 and 342 ofFIG. 4 ) for connection to the adjacent receivers, e.g., as described with reference toFIG. 3 . Theconnector 840, is in some implementations, securely attached to theboard 809 and may be constructed out of an insulating material (e.g., plastic). - The relatively
large connector 840 helps prevent a solar cell breakdown as a result of electric discharges at the terminals leading to adjacent receivers, owing to the insulated apertures providing an excellent insulation for each of the plug/socket electrical connections housed therein. - The
diode 814 is coated with aglobtop dielectric coating 816. Also, a dielectric underfill is placed beneath thediode 814 between theterminals FIG. 5 (e.g.,items 15 and 16). - VII. Other Results
- In addition to solving the problem of uncontrolled discharge, the use of the underfill and/or globtop (e.g., conformal coating) can result in additional, unexpected, advantages.
- Using underfill and/or globtop can substantially improve the ability of a receiver to manage heat dissipation. The underfill and globtop dielectric materials (e.g., 15 and 16) have a higher thermal conductivity than air. Consequently, they improve heat dissipation from the components of the system to the surrounding ambient atmosphere by increasing the cross-section of the thermal path. Moreover, because the underfill and globtop dielectric materials (e.g., 15 and 16) are, in some implementations, in contact with the board or substrate, they facilitate heat transfer from the diode to the board. For example, the
underfill 15 andglobtop 16 substantially improve the heat dissipation of thediode 14. As described above, when bypassing thesolar cell 30, thediode 14 may be carrying several thousand (e.g., 10,000) watts of electrical power. Because diodes are not perfectly efficient electrical conductors, some of that power is dissipated as thermal energy. Excessive thermal energy can destroy the diode, and at a minimum, reduce its service life. As a result, receivers that employ underfill and/or globtop are likely to have increased service life, especially as power levels increase. Moreover, the underfill and/or globtop is a much more cost effective, efficient and lighter solution than many other methods (e.g., passive cooling using metal heat sinks or active cooling) for improving heat management. Moreover, those other methods do not solve the problem of uncontrolled discharge. - The underfill and/or globtop materials can also protect against short circuits resulting from contaminants. In some implementations, the conductor traces (e.g.,
items 45 and 46) are separated by no more than approximately 1 mm (0.394 inches). When traces are this close to each other, many contaminants, such as a droplet of water, are sufficiently large to contact two adjacent conductor traces. Moreover, as thediode 14 is itself relatively small, it is possible for one or more water droplets to bridgeterminals diode 14 or on the conductor traces 45 and 46, thereby reducing the probability of short circuits. - The underfill and/or dielectric globtop (or conformal coating)
materials diodes 14, onto the conductor traces 45 and 46 and onto any electrical traces on theboard 9, thereby further reducing the probability of short circuits during operation. - Another unexpected advantage is that the underfill and/or globtop dielectric materials (e.g., 15 and 16) add mechanical integrity to the interfaces between the diodes and the boards to which they are attached. As a result, during transport, installation and handling, the likelihood of the diode becoming detached (or otherwise electrically de-coupled) is reduced.
- VIII. Typical Performance Data
- Testing implementations of solar cell receivers (e.g., item 12) at different solar concentrations resulted in the following data. The testing at 470 Suns and 1150 Suns involved utilization of the
solar cell receiver 12 as part of a solar cell module assembly (e.g., item 20). -
1 Sun 470 Suns 1150 Suns Efficiency 31.23% 36.23% 33.07% Voc (open circuit 2.583 V 3.051 V 3.078 V voltage) Jsc (short circuit 13.9 mA/cm2 6.49 A/cm2 15.92 A/cm2 current) Vmp (voltage at 2.32 V 2.704 V 2.523 V maximum power point) Jmp (current at 13.46 mA/cm2 6.27 A/cm2 15.04 A/cm2 maximum power point) Pmp (maximum 31.23 mW/cm2 17.03 W/cm2 38.03 W/cm2 power point) - As indicated, the testing revealed that efficiency was highest at 470 Suns concentration. Although 1150 Suns produced greater overall output, the greater concentration exposes the solar cell to a greater amount of heat which may damage or substantially shorten the life of the solar cell.
- It will be apparent that modifications could be made to the apparatus described above. In particular, the dielectric material could be applied not only to the diodes, but also to all terminals, leads, and conductor traces on the panel. Moreover, the solar cell module housings can be made adjustable, for example, (1) to accommodate lenses having different focal lengths or (2) to increase or decrease concentration (i.e., Suns) by moving the solar cell away from or toward the focal point. Moreover, multiple lenses may be arrayed, for example, to focus incoming light precisely onto the solar cell.
- A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other implementations are within the scope of the claims.
Claims (10)
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Cited By (18)
Publication number | Priority date | Publication date | Assignee | Title |
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US20090032093A1 (en) * | 2007-07-30 | 2009-02-05 | Lu Fang | Solar Cell Receiver Having An Insulated Bypass Diode |
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Also Published As
Publication number | Publication date |
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KR20090086906A (en) | 2009-08-14 |
US20090199890A1 (en) | 2009-08-13 |
KR101224923B1 (en) | 2013-01-23 |
CN101510571A (en) | 2009-08-19 |
JP5150879B2 (en) | 2013-02-27 |
JP2009188410A (en) | 2009-08-20 |
TW200941749A (en) | 2009-10-01 |
DE102009006286A1 (en) | 2009-10-01 |
CN101510571B (en) | 2014-03-26 |
US8093492B2 (en) | 2012-01-10 |
ES2378392A1 (en) | 2012-04-12 |
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