WO2006133126A2 - Procede et systeme d'integration d'une cellule solaire au moyen d'une pluralite de regions photovoltaiques - Google Patents

Procede et systeme d'integration d'une cellule solaire au moyen d'une pluralite de regions photovoltaiques Download PDF

Info

Publication number
WO2006133126A2
WO2006133126A2 PCT/US2006/021803 US2006021803W WO2006133126A2 WO 2006133126 A2 WO2006133126 A2 WO 2006133126A2 US 2006021803 W US2006021803 W US 2006021803W WO 2006133126 A2 WO2006133126 A2 WO 2006133126A2
Authority
WO
WIPO (PCT)
Prior art keywords
region
photovoltaic
substrate member
solar cell
photovoltaic strips
Prior art date
Application number
PCT/US2006/021803
Other languages
English (en)
Other versions
WO2006133126A3 (fr
Inventor
Kevin R. Gibson
Original Assignee
Solaria Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US11/445,933 external-priority patent/US20060283495A1/en
Application filed by Solaria Corporation filed Critical Solaria Corporation
Priority to EP06760692A priority Critical patent/EP1902475A2/fr
Priority to JP2008515807A priority patent/JP2008543111A/ja
Publication of WO2006133126A2 publication Critical patent/WO2006133126A2/fr
Publication of WO2006133126A3 publication Critical patent/WO2006133126A3/fr

Links

Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • 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
    • H01L31/042—PV modules or arrays of single PV cells
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • 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
    • H01L31/0543—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
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • 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
    • H01L31/042—PV modules or arrays of single PV cells
    • H01L31/048—Encapsulation of modules
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • 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
    • H01L31/18—Processes or apparatus specially adapted for the manufacture or treatment of these devices or of parts thereof
    • 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
    • H02S40/00—Components or accessories in combination with PV modules, not provided for in groups H02S10/00 - H02S30/00
    • H02S40/20—Optical components
    • H02S40/22—Light-reflecting or light-concentrating means
    • 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

Definitions

  • the present invention relates generally to solar energy techniques.
  • the present invention provides a method and resulting device fabricated from a plurality of photovoltaic regions provided within one or more substrate members. More particularly, the present invention provides a method and resulting device for manufacturing the photovoltaic regions within the substrate member, which is coupled to a plurality of concentrating elements.
  • the invention has been applied to solar panels, commonly termed modules, but it would be recognized that the invention has a much broader range of applicability.
  • Solar panels have been developed to convert sunlight into energy.
  • solar thermal panels often convert electromagnetic radiation from the sun into thermal energy for heating homes, running certain industrial processes, or driving high grade turbines to generate electricity.
  • solar photovoltaic panels convert sunlight directly into electricity for a variety of applications.
  • Solar panels are generally composed of an array of solar cells, which are interconnected to each other. The cells are often arranged in series and/or parallel groups of cells in series. Accordingly, solar panels have great potential to benefit our nation, security, and human users. They can even diversify our energy requirements and reduce the world's dependence on oil and other potentially detrimental sources of energy.
  • the present invention provides a method and resulting device fabricated from a plurality of photovoltaic regions provided within one or more substrate members. More particularly, the present invention provides a method and resulting device for manufacturing the photovoltaic regions within the substrate member, which is coupled to a plurality of concentrating elements.
  • the invention has been applied to solar panels, commonly termed modules, but it would be recognized that the invention has a much broader range of applicability.
  • the present invention provides a method for fabricating a solar cell, which may be free and separate from a solar panel.
  • the solar cell may be packaged as a solar panel.
  • the method forms the solar cell separate from the panel.
  • One or more solar cells are then assembled onto the panel to complete the solar panel device according to a specific embodiment.
  • the method includes providing a first substrate member comprising a plurality of photovoltaic strips thereon and providing an optical elastomer material overlying a portion of the first substrate member.
  • the method also includes aligning a second substrate member comprising a plurality of optical concentrating elements thereon such that at least one of the optical concentrating elements is operably coupled to at least one of the one of the plurality of photovoltaic strips, e.g., regions.
  • the method includes coupling the first substrate member to the second substrate member to form an interface region along a peripheral region of the first substrate member and the second substrate member. In a preferred embodiment, the coupling is provided by joining the substrates with the elastomer material in between them.
  • the method also includes sealing the interface region to form an individual solar cell from at least the first substrate and the second substrate. [0013] In an alternative specific embodiment, the invention mcm ⁇ es a memo ⁇ ior fabricating another solar cell.
  • the method includes providing a first substrate member comprising a plurality of photovoltaic regions thereon.
  • the photovoltaic regions can be strips, squares, trapezoids, annular regions (of symmetry or non- symmetry), or any combination of these, and other shapes.
  • the method includes providing an encapsulating material overlying a portion of the first substrate member.
  • the method includes aligning a second substrate member to the first substrate member.
  • the method couples the first substrate member to the second substrate member to form an interface region along a peripheral region of the first substrate member and the second substrate member.
  • the method seals the interface region to form an individual solar cell structure from the first substrate and the second substrate.
  • the present invention provides a solar cell device.
  • the device has a first substrate member and a plurality of photovoltaic strips overlying the first substrate member.
  • the device also has an optical elastomer material overlying a portion of the first substrate member and has a second substrate member comprising a plurality of optical concentrating elements thereon.
  • the second substrate member is overlying a the plurality of photovoltaic strips such that at least one of the optical concentrating elements is operably coupled to at least one of the one of the plurality of photovoltaic strips.
  • the device has an interface region along a peripheral region of the first substrate member and the second substrate member.
  • the device also has a sealed region at the interface region to form an individual solar cell from the first substrate member and the second substrate member.
  • the present invention provides yet an alternative solar cell device structure.
  • the device structure has a first substrate member, which has spatial region Al, which may be defined as a first area given in units 2 , e.g., centimeters 2 .
  • the first square area relates to a surface region of the first substrate member.
  • the device also has a plurality of photovoltaic regions overlying the first substrate member. The plurality of photovoltaic regions are occupying a total photovoltaic spatial region A(2), which may be defined as a second square area.
  • the device has an encapsulating material overlying a portion of the first substrate member and has a second substrate member coupled to the encapsulating material.
  • the device has an interface region along a peripheral region of the first substrate member and the second substrate member and a sealed region at the interface region to form an individual solar cell from the first substrate member and the second substrate member.
  • the device is characterized by a ratio of A(2)/A(l) that is about 0.80 and less for the individual solar cell.
  • the present invention provides an alternative solar cell device structure.
  • the device structure has a back cover member, which includes a surface area and a back area.
  • the device structure also has a plurality of photovoltaic regions disposed overlying the surface area of the back cover member. In a preferred embodiment, the plurality of photovoltaic regions occupies a total photovoltaic spatial region.
  • the device has an encapsulating material overlying a portion of the back cover member and has a front cover member coupled to the encapsulating material.
  • An interface region is provided along at least a peripheral region of the back cover member and the front cover member.
  • a sealed region is formed on at least the interface region to form an individual solar cell from the back cover member and the front cover member.
  • the total photovoltaic spatial region/the surface area of the back cover is at a ratio of about 0.50 and less for the individual solar cell. Alternatively, other ratios such as 0.8 and less can exist depending upon the specific embodiment.
  • the terms “back cover member” and “front cover member” are provided for illustrative purposes, and not intended to limit the scope of the claims to a particular configuration relative to a spatial orientation according to a specific embodiment.
  • the present invention provides an alternative solar cell device.
  • the device has a first substrate member and a plurality of photovoltaic strips overlying the first substrate member.
  • the device has an encapsulant material overlying a portion of the first substrate member.
  • the device has a first refractive index characterizing the encapsulant material, and has a second substrate member comprising a plurality of optical concentrating elements thereon.
  • the second substrate member is overlying the plurality of photovoltaic strips such that at least one of the optical concentrating elements is operably coupled to at least one of the one of the plurality of photovoltaic strips.
  • the plurality of concentrating elements is composed by at least a second substrate material.
  • the device has a second refractive index characterizing the second substrate material.
  • the second refractive index is substantially matched to the first refractive index to cause one or more photons to traverse through at least one of the optical concentrating elements through a portion of the encapsulant and to a portion of one of the photovoltaic strips to reduce an amount of internal reflection from a portion of the one concentrating element.
  • the reduced amount of internal reflection causes an increase of a quantity of photons reaching a photovoltaic region.
  • the present invention provides a solar cell device with improved encapsulant material.
  • the device has a first substrate member and a plurality of photovoltaic strips overlying the first substrate member.
  • the device has an encapsulant material overlying a portion of the first substrate member.
  • the device has a first refractive index characterizing the encapsulant material, and has a second substrate member comprising a plurality of optical concentrating elements thereon.
  • the second substrate member is overlying the plurality of photovoltaic strips such that at least one of the optical concentrating elements is operably coupled to at least one of the one of the plurality of photovoltaic strips.
  • the plurality of concentrating elements is composed by at least a second substrate material.
  • the device has a second refractive index characterizing the second substrate material.
  • the first refractive index of the encapsulant material is substantially matched with the second refractive index to facilitate a transfer of one or more photons from at least one of the optical concentrating elements to a portion of one of the photovoltaic strips in a preferred embodiment.
  • the present invention provides a packaged solar cell assembly being capable of stand-alone operation to generate power using the packaged solar cell assembly and/or with other solar cell assemblies.
  • the packaged solar cell assembly includes rigid front cover member having a front cover surface area and a plurality of concentrating elements thereon. Each of the concentrating elements has a length extending from a first portion of the front cover surface area to a second portion of the front cover surface area. Each of the concentrating elements has a width provided between the first portion and the second portion. Each of the concentrating elements having a first edge region coupled to a first side of the width and a second edge region provided on a second side of the width.
  • the first edge region and the second edge region extend from the first portion of the front cover surface area to a second portion of the front cover surface area.
  • the plurality of concentrating elements is configured in a parallel manner extending from the first portion to the second portion, hi addition, the packaged solar cell assembly includes a plurality of photovoltaic strips arranged respectively on the plurality of concentrating elements. Each of the plurality of photovoltaic strips has a strip width and a strip length. Each of the photovoltaic strips coupling at least one of the plurality of concentrating elements.
  • the packaged solar cell assembly additionally includes a coupling material provided between each of the photovoltaic strips and each of the concentrating elements to optical couple the photovoltaic strip to the concentrating element.
  • the packaged solar cell assembly further includes a rigid back cover member.
  • the back cover member has a plurality of support regions.
  • the plurality of support regions provides respectively mechanical support to respective plurality of photovoltaic strips.
  • the package solar cell assembly includes a sealed region to mechanically couple the rigid back cover member to the rigid front cover member to provide a sealed sandwiched assembly capable of maintaining the plurality of photovoltaic strips substantially free from moisture. The sealed sandwiched assembly can be handled while maintaining the plurality of photovoltaic strips substantially free from mechanical damage.
  • the present invention provides a solar cell apparatus.
  • the solar cell apparatus includes a backside substrate member comprising a backside surface region and an inner surface region.
  • the solar cell apparatus also includes a plurality of photovoltaic strips spatially disposed in a parallel manner overlying the inner surface region. Each of the photovoltaic strips being characterized by a length and a width.
  • the solar cell apparatus additionally includes a shaped concentrator device operably coupled to each of the plurality of photovoltaic strips.
  • the shaped concentrator device has a first side and a second side.
  • the solar cell apparatus includes an aperture region provided on the first side of the shaped concentrator device.
  • the solar cell apparatus includes an exit region provided on the second side of the shaped concentrator device.
  • the solar cell apparatus includes a geometric concentration characteristic provided by a ratio of the aperture region to the exit region. The ratio can be characterized by a range from about 1.8 to about 4.5.
  • the solar cell apparatus also includes a polymer material characterizing the shaped concentrator device.
  • the solar cell apparatus additionally includes a refractive index of about 1.45 and greater characterizing the polymer material of the shaped concentrator device.
  • the solar cell apparatus includes a coupling material formed overlying each of the plurality of photovoltaic strips and coupling each of the plurality of photovoltaic regions to each of the concentrator devices.
  • the solar cell apparatus includes a refractive index of about 1.45 and greater characterizing the coupling material coupling each of the plurality of photovoltaic regions to each of the concentrator device.
  • the present invention provides a solar cell apparatus.
  • the solar cell apparatus includes a backside substrate member, which includes a backside surface region and an inner surface region.
  • the backside substrate member is characterized by a width.
  • the solar cell apparatus also includes a plurality of photovoltaic strips spatially disposed in a parallel manner overlying the inner surface region. Each of the photovoltaic strips can be characterized by a length and a width.
  • the solar cell apparatus includes a shaped concentrator device operably coupled to each of the plurality of photovoltaic strips.
  • the shaped concentrator device has a first side and a second side.
  • the solar cell apparatus includes an aperture region provided on the first side of the shaped concentrator device.
  • the solar cell apparatus also includes an exit region provided on the second side of the shaped concentrator device.
  • the solar cell apparatus additionally includes a first reflective side provided between a first portion of the aperture region and a first portion of the exit region.
  • the solar cell apparatus includes a second reflective side provided between a second portion of the aperture region and a second portion of the exit region, hi addition, the solar cell apparatus includes a geometric concentration characteristic provided by a ratio of the aperture region to the exit region. The ratio is characterized by a range from about 1.8 to about 4.5.
  • the solar cell apparatus includes a polymer material characterizing the shaped concentrator device, which includes the aperture region, exit region, first reflective side, and second reflective side.
  • the solar cell apparatus has a refractive index of about 1.45 and greater characterizing the polymer material of the shaped concentrator device.
  • the solar cell apparatus includes a coupling material formed overlying each of the plurality of photovoltaic strips and coupling each of the plurality of photovoltaic regions to each of the concentrator devices.
  • the solar cell apparatus additionally includes one or more pocket regions facing each of the first reflective side and the second reflective side. The one or more pocket regions can be characterized by a refractive index of about 1 to cause one or more photons from the aperture region to be reflected toward the exit region.
  • the present invention provides a packaged solar cell assembly that is capable of stand-alone operation to generate power using the packaged solar cell assembly and/or with other solar cell assemblies.
  • the packaged solar cell assembly includes a rigid front cover member having a plurality of concentrating elements thereon.
  • each of the concentrating elements is arranged in a parallel manner extending from a first portion to a second portion of the front cover member.
  • the plurality of concentrating elements in the parallel manner is configured in a stripe arrangement from the first portion to the second portion.
  • Each of the concentrating elements has an optical concentration of at least one and one half.
  • the cell assembly additionally includes a maximum spatial dimension of no greater than eight and one half inches between the first portion and the second portion of the rigid front cover member.
  • the cell assembly includes a plurality of photovoltaic strips arranged respectively on the plurality of optical concentrating elements. Each of the plurality of photovoltaic strips has a strip width and a strip length. Each of the photovoltaic strips is coupling at least one of the plurality of concentrating elements.
  • the present invention provides a packaged solar cell assembly.
  • the assembly has a rigid front cover member having a plurality of concentrating elements thereon.
  • Each of the concentrating elements is arranged in a substantially parallel manner extending from a first portion to a second portion of the front cover member.
  • the plurality of concentrating elements in the substantially parallel manner is configured in a stripe arrangement from the first portion to the second portion.
  • Each of the concentrating elements has an optical concentration of at least one and one half.
  • the assembly has a maximum spatial dimension of no greater than eight and one half inches between the first portion and the second portion of the rigid front cover member.
  • the assembly also has a plurality of photovoltaic strips arranged respectively on the plurality of optical concentrating elements.
  • Each of the plurality of photovoltaic strips has a strip width and a strip length. Each of the photovoltaic strips is coupling at least one of the plurality of concentrating elements.
  • One or more first electrical member(s) couples a first portion of each of the plurality of photovoltaic strips.
  • One or more second electrical member(s) couples a second portion of each of the plurality of photovoltaic strips.
  • the assembly also has an optical coupling material provided between each of the photovoltaic strips and each of the concentrating elements to optically couple the photovoltaic strip to the concentrating element.
  • a rigid back cover member is also provided.
  • the back cover member has a plurality of support regions. The plurality of support regions are provided respectively mechanical support to respective plurality of photovoltaic strips.
  • a sealed region mechanically couples the rigid back cover member to the rigid front cover member to provide a sealed sandwiched assembly capable of maintaining the plurality of photovoltaic strips substantially free from moisture.
  • the sealed sandwiched assembly is capable of being handled while maintaining the plurality of photovoltaic strips substantially free from mechanical damage.
  • Each of the concentrating elements has a pair of sides, which have a surface finish of 120 nm or less RMS to cause light to be substantially internally reflected.
  • the present technique provides an easy to use process that relies upon conventional technology such as silicon materials, although other materials can also be used.
  • the method provides a process that is compatible with conventional process technology without substantial modifications to conventional equipment and processes.
  • the invention provides for an improved solar cell, which is less costly and easy to handle.
  • Such solar cell uses a plurality of photovoltaic regions, which are sealed within one or more substrate structures according to a preferred embodiment.
  • the invention provides a method and completed solar cell structure using a plurality of photovoltaic strips free and clear from a module or panel assembly, which are provided during a later assembly process.
  • one or more of the solar cells have less silicon per area (e.g., 80% or less, 50% or less) than conventional solar cells.
  • the present method and cell structures are also light weight and not detrimental to building structures and the like. That is, the weight is about the same or slightly more than conventional solar cells at a module level according to a specific embodiment.
  • the present solar cell using the plurality of photovoltaic strips can be used as a "drop in" replacement of conventional solar cell structures.
  • the present solar cell can be used with conventional solar cell technologies for efficient implementation according to a preferred embodiment. Depending upon the embodiment, one or more of these benefits may be achieved. These and other benefits will be described in more detail throughout the present specification and more particularly below.
  • Figure 1 is a simplified diagram illustrating an expanded view of a solar cell structure according to an embodiment of the present invention
  • Figure 2 is a simplified diagram of a back cover structure according to an embodiment of the present invention.
  • Figure 2A is a detailed diagram of the back cover structure according to an embodiment of the present invention
  • Figure 3 is a simplified diagram illustrating a method of attaching a plurality of photovoltaic strips to the back cover structure according to an embodiment of the present invention
  • Figure 4 is a simplified diagram of an assembled back cover and photovoltaic strips according to an embodiment of the present invention.
  • Figure 5 is a simplified diagram illustrating a method of providing an encapsulant overlying the assembled back cover and photovoltaic strips according to an embodiment of the present invention
  • Figure 6 is a simplified diagram of an assembled back cover, photovoltaic strips, and encapsulant according to an embodiment of the present invention
  • Figure 7 is a simplified diagram illustrating a method of assembling a front cover overlying the assembled back cover, photovoltaic strips, and encapsulant according to an embodiment of the present invention
  • Figure 8 is a more detailed diagram illustrating a plurality concentrating elements on a front cover according to an embodiment of the present invention.
  • Figure 8 A is a further detailed diagram illustrating the plurality of concentrating elements on the front cover according to an embodiment of the present invention.
  • Figure 9 is a simplified diagram illustrating an assembled solar cell structure according to an embodiment of the present invention.
  • Figure 9A is a more detailed diagram illustrating the assembled solar cell structure according to an embodiment of the present invention.
  • FIG. 10 is a simplified diagram of a concentrator assembly according to an embodiment of the present invention
  • the present invention provides a method and resulting device fabricated from a plurality of photovoltaic regions provided within one or more substrate members. More particularly, the present invention provides a method and resulting device for manufacturing the photovoltaic regions within the substrate member, which is coupled to a plurality of concentrating elements.
  • the invention has been applied to solar panels, commonly termed modules, but it would be recognized that the invention has a much broader range of applicability.
  • a method for fabricating a solar cell structure according to an embodiment of the present invention may be outlined as follows:
  • the above sequence of steps provides a method according to an embodiment of the present invention.
  • the method uses a combination of steps including a way of forming a solar cell for a solar panel, which has a plurality of solar cells.
  • steps are added, one or more steps are removed, or one or more steps are provided in a different sequence without departing from the scope of the claims herein.
  • the plurality of photovoltaic strips are coupled to the second substrate and then the first substrate is provided and sealed to the second substrate.
  • a coupling material is provided between the second substrate, which includes a plurality of concentrating elements, and the plurality of photovoltaic strips.
  • FIG. 1 an expanded view 10 of a solar cell structure according to an embodiment of the present invention is illustrated.
  • the device has a back cover member 101, which includes a surface area and a back area.
  • the back cover member also has a plurality of sites, which are spatially disposed, for electrical members, such as bus bars, and a plurality of photovoltaic regions.
  • the back cover can be free from any patterns and is merely provided for support and packaging.
  • the device has a plurality of photovoltaic strips 105, each of which is disposed overlying the surface area of the back cover member.
  • the plurality of photovoltaic strips correspond to a cumulative area occupying a total photovoltaic spatial region, which is active and converts sunlight into electrical energy.
  • An encapsulating material 115 is overlying a portion of the back cover member. That is, an encapsulating material forms overlying the plurality of strips, and exposed regions of the back cover, and electrical members.
  • the encapsulating material can be a single layer, multiple layers, or portions of layers, depending upon the application.
  • the encapsulating material can be provided overlying a portion of the photovoltaic strips or a surface region of the front cover member, which would be coupled to the plurality of photovoltaic strips.
  • a front cover member 121 is coupled to the encapsulating material. That is, the front cover member is formed overlying the encapsulant to form a multilayered structure including at least the back cover, bus bars, plurality of photovoltaic strips, encapsulant, and front cover.
  • the front cover includes one or more concentrating elements, which concentrate (e.g., intensify per unit area) sunlight onto the plurality of photovoltaic strips. That is, each of the concentrating elements can be associated respectively with each of or at least one of the photovoltaic strips.
  • an interface region is provided along at least a peripheral region of the back cover member and the front cover member.
  • the interface region may also be provided surrounding each of the strips or certain groups of the strips depending upon the embodiment.
  • the device has a sealed region and is formed on at least the interface region to form an individual solar cell from the back cover member and the front cover member.
  • the sealed region maintains the active regions, including photovoltaic strips, in a controlled environment free from external effects, such as weather, mechanical handling, environmental conditions, and other influences that may degrade the quality of the solar cell.
  • the sealed region and/or sealed member (e.g., two substrates) protect certain optical characteristics associated with the solar cell and also protects and maintains any of the electrical conductive members, such as bus bars, interconnects, and the like.
  • the sealed member structure there can be other benefits achieved using the sealed member structure according to other embodiments.
  • the total photovoltaic spatial region occupies a smaller spatial region than the surface area of the back cover. That is, the total photovoltaic spatial region uses less silicon than conventional solar cells for a given solar cell size. In a preferred embodiment, the total photovoltaic spatial region occupies about 80% and less of the surface area of the back cover for the individual solar cell. Depending upon the embodiment, the photovoltaic spatial region may also occupy about 70% and less or 60% and less or preferably 50% and less of the surface area of the back cover or given area of a solar cell. Of course, there can be other percentages that have not been expressly recited according to other embodiments.
  • back cover member and “front cover member” are provided for illustrative purposes, and not intended to limit the scope of the claims to a particular configuration relative to a spatial orientation according to a specific embodiment. Further details of each of the various elements in the solar cell can be found throughout the present specification and more particularly below.
  • the present invention provides a packaged solar cell assembly being capable of stand-alone operation to generate power using the packaged solar cell assembly and/or with other solar cell assemblies.
  • the packaged solar cell assembly includes rigid front cover member having a front cover surface area and a plurality of concentrating elements thereon.
  • the rigid front cover member consist of a variety of materials.
  • the rigid front cover is made of polymer material.
  • the rigid front cover is made of transparent polymer material having a reflective index of about 1.4 or 1.42 or greater.
  • the rigid front cover has a Young's Modulus of a suitable range.
  • Each of the concentrating elements has a length extending from a first portion of the front cover surface area to a second portion of the front cover surface area.
  • Each of the concentrating elements has a width provided between the first portion and the second portion.
  • Each of the concentrating elements having a first edge region coupled to a first side of the width and a second edge region provided on a second side of the width. The first edge region and the second edge region extend from the first portion of the front cover surface area to a second portion of the front cover surface area.
  • the plurality of concentrating elements is configured in a parallel manner extending from the first portion to the second portion.
  • embodiment can have many variations.
  • the embodiment may further includes a first electrode member that is coupled to a first region of each of the plurality of photovoltaic strips and a second electrode member coupled to a second region of each of the plurality of photovoltaic strips.
  • the solar cell assembly additionally includes a first electrode member coupled to a first region of each of the plurality of photovoltaic strips and a second electrode member coupled to a second region of each of the plurality of photovoltaic strips.
  • the first electrode includes a first protruding portion extending from a first portion of the sandwiched assembly and the second electrode comprising a second protruding portion extending from a second portion of the sandwiched assembly.
  • the present invention provides a solar cell apparatus.
  • the solar cell apparatus includes a backside substrate member comprising a backside surface region and an inner surface region.
  • the backside substrate member can be made from various materials.
  • the backside member is characterized by a polymer material.
  • the present invention provides a solar cell apparatus that includes a backside substrate member.
  • the backside substrate member includes a backside surface region and an inner surface region.
  • the backside substrate member is characterized by a width.
  • the backside substrate member is characterized by a length of about eight inches and less.
  • the backside substrate member is characterized by a width of about 8 inches and less and a length of more than 8 inches.
  • FIG. 2 is a simplified diagram of a back cover structure 100 according to an embodiment of the present invention.
  • the back cover has a bottom region 205 and a surface region 201, which includes a plurality of recessed regions 209.
  • Each of the recessed regions corresponds to a spatial site for a photovoltaic material according to a specific embodiment, m a specific embodiment, the recessed region provides a mechanical and physical site for a photovoltaic strip or region of photovoltaic material.
  • An area occupied by the recessed regions is surrounded by a peripheral region 203, which has an edge region 211 protruding slightly higher along a y-direction than the inner recessed regions according to a specific embodiment.
  • a peripheral region 203 which has an edge region 211 protruding slightly higher along a y-direction than the inner recessed regions according to a specific embodiment.
  • the back cover also includes one or more conducting members, which are often bus bars 207.
  • Each of the bus bars can couple a plurality of strips together in serial, parallel, or a combination of these configurations electrically.
  • each of the bus bars is provided normal to a plurality of recessed regions. That is, each of the bus bars runs along an x-direction, while each of the recessed regions runs along a z-direction according to a specific embodiment.
  • the bus bars are merely illustrative and not comprehensive. That is, there may be other bus bars (not shown) that run parallel to each of the recessed regions, or angular to each of the recessed regions, or any combination of these configurations. Further details of the conducting members can be found in the above Gibson Provisional Patent Application, commonly assigned, and hereby incorporated by reference herein. Of course, there can be other variations, modifications, and alternatives.
  • the back cover can be made of a variety of suitable materials or combination of materials and layers.
  • the back cover can be made using a polymer bearing material according to a specific embodiment.
  • the polymer material may be a non-conductive material according to a preferred embodiment.
  • the back cover can be a single layer or a multilayered material, and is preferably not optically transparent, but may also be optically transparent according to other embodiments.
  • the back cover uses a polymer material that has been molded or machined to form the plurality of recessed regions and other desired characteristics.
  • the rigid back cover member can be made of a variety of materials.
  • the back front cover is made of polymer material, a glass, or other suitable material.
  • the rigid back cover has a suitable Young's Modulus.
  • the plurality of support regions provides respectively mechanical support to respective plurality of photovoltaic strips.
  • the package solar cell assembly includes a sealed region to mechanically couple the rigid back cover member to the rigid front cover member to provide a sealed sandwiched assembly capable of maintaining the plurality of photovoltaic strips substantially free from moisture.
  • the moisture is less than a predetermined amount in parts per million to prevent corrosion and facilitate operation of the solar cell device.
  • the sealed sandwiched assembly can be handled while maintaining the plurality of photovoltaic strips substantially free from mechanical damage.
  • mechanical damage is breakage of one or more of the photovoltaic strips.
  • a detailed view of the back cover is provided in reference to Figure 2A. As shown, a top-view 210 of the back cover is illustrated. Alternative views are also provided. For example, a cross-section "A-A" 220 is illustrated. Such A-A cross section is along a region for a bus bar member according to a specific embodiment. Detail “F” 280 and detail “E” 260 are also illustrated. Detail F corresponds to a peripheral or edge region of the back cover. Similarly, detail F corresponds to an alternative peripheral or edge region of the back cover.
  • Cross sections "B-B” and “C-C" 230, 240 are also illustrated. Such cross-sections B-B and C-C relate to respective recessed region lengths along the back cover.
  • FIG. 3 is a simplified diagram 300 illustrating a method of attaching a plurality of photovoltaic strips 105 to the back cover structure 100 according to an embodiment of the present invention.
  • This diagram is merely an example, which should not unduly limit the scope of the claims herein.
  • the photovoltaic strips are each aligned to a respective recessed region.
  • Each of the photovoltaic strips has a predetermined width, length, and depth to allow it to fit within a portion of the recessed region or other physical site depending upon the embodiment.
  • each of the photovoltaic strips is made of a silicon bearing material, which includes a photo energy conversion device therein.
  • each of the strips is made of single crystal and/or poly crystalline silicon that have suitable characteristics to cause it to convert applied sunlight or electromagnetic radiation into electric current energy according to a specific embodiment.
  • An example of such a strip is called the Sliver Cell® product manufactured by Origin Energy of Australia, but can be others.
  • the strip can be provided from a conventional solar cell. That is, the strip can be provided by dicing (e.g., saw, scribe and break) a conventional solar cell or suitably designed solar cell according to a specific embodiment.
  • the conventional solar cell can be a back contact cell manufactured by
  • the strips or regions of photovoltaic material can be made of other suitable materials such as other semiconductor materials, including semiconductor elements listed in the Periodic Table of Elements, polymeric materials that have photovoltaic properties, or any combination of these, and the like.
  • suitable materials such as other semiconductor materials, including semiconductor elements listed in the Periodic Table of Elements, polymeric materials that have photovoltaic properties, or any combination of these, and the like.
  • a packaged solar cell assembly includes a plurality of photovoltaic strips arranged respectively on the plurality of concentrating elements. Each of the plurality of photovoltaic strips has a strip width and a strip length. Each of the photovoltaic strips coupling at least one of the plurality of concentrating elements.
  • the packaged solar cell assembly additionally includes a coupling material provided between each of the photovoltaic strips and each of the concentrating elements to optical couple the photovoltaic strip to the concentrating element.
  • the solar cell apparatus also includes a plurality of photovoltaic strips spatially disposed in a parallel manner overlying the inner surface region.
  • Each of the photovoltaic strips being characterized by a length and a width.
  • each of the photovoltaic strips includes a plurality of p-type regions and a plurality of n-type regions. Each of the p-type regions is coupled to at least one of the n-type region.
  • the photovoltaic strips are made of silicon material.
  • the solar cell apparatus includes a plurality of photovoltaic strips spatially disposed in a parallel manner overlying the inner surface region.
  • the solar cell apparatus includes a shaped concentrator device operably coupled to each of the plurality of photovoltaic strips.
  • the shaped concentrator device has a first side and a second side.
  • the solar cell apparatus includes an aperture region provided on the first side of the shaped concentrator device.
  • the solar cell apparatus also includes an exit region provided on the second side of the shaped concentrator device.
  • FIG 4 is a simplified diagram 400 of an assembled back cover and photovoltaic strips according to an embodiment of the present invention.
  • This diagram is merely an example, which should not unduly limit the scope of the claims herein.
  • One of ordinary skill in the art would recognize many variations, modifications, and alternatives.
  • each of the photovoltaic strips has been provided in a respective recessed region or site on the back cover.
  • Each of the strips is preferably mechanically secure onto the recessed region in a specific embodiment.
  • a first group of strips may be coupled to at least one of the bus bars and a second group of strips may be coupled to another group of bus bars.
  • Each of the strips is coupled to at least two of the bus bars or like conduction members to provide an electrical circuit for providing electrical power.
  • the back cover can be provided onto an assembled front cover and photovoltaic strip structure according to an alternative embodiment of the present invention.
  • FIG. 5 is a simplified diagram 500 illustrating a method of providing an encapsulant 115 overlying the assembled back cover and photovoltaic strips according to an embodiment of the present invention.
  • This diagram is merely an example, which should not unduly limit the scope of the claims herein.
  • the encapsulant can be a single layer 115 or multiple layers according to a specific embodiment.
  • the encapsulant may also be provided in liquid form, which is cured to enclose and seal each of the photovoltaic strips and portions of the bus bar members in a specific embodiment.
  • the encapsulant is made of a suitable material for desired optical, electrical, and physical characteristics.
  • the optical is preferably an optical elastomer material, which begins as a liquid and cures to form a solid material.
  • the elastomer material has suitable thermal and optical characteristics. That is, a refractive index of the elastomer material is substantially matched to a overlying front cover according to a specific embodiment.
  • the encapsulant material adapts for a first coefficient of thermal expansion of the plurality of photovoltaic strips on the first substrate member and a second coefficient of thermal expansion associated with the second substrate.
  • the encapsulant material facilitates transfer of one of more photons between one of the concentrating elements and one of the plurality of photovoltaic strips.
  • the encapsulant material can act as a barrier material, an electrical isolating structure, a glue layer, and other desirable features.
  • the term "elastomer” should be given its broadest interpretation according to one of ordinary skill in the art. Of course, there can be other variations, modifications, and alternatives.
  • the sealed sandwiched assembly is capable of being handled while maintaining the plurality of photovoltaic strips substantially free from mechanical damage.
  • the sealed region includes ultrasonic (e.g., 15 to 30 kilo- Hertz) welded portion.
  • the sealed region is provided by a vibrational welded portion, a thermal formed portion, a chemical formed portion, a glued portion, an adhered portion, or an irradiated portion, e.g., laser.
  • the sealed sandwiched assembly has a total thickness of 7 millimeters or less.
  • the sealed sandwiched assembly has a width ranging from about 100 millimeters to about 210 millimeters and a length ranging from about 100 millimeters to about 210 millimeters.
  • the sealed sandwiched assembly can even have a length of about 300 millimeters and greater.
  • FIG. 6 is a simplified diagram 600 of an assembled back cover, photovoltaic strips, and encapsulant according to an embodiment of the present invention.
  • This diagram is merely an example, which should not unduly limit the scope of the claims herein.
  • the encapsulant has been formed overlying surfaces of the photovoltaic strips provided in the recessed regions and portions of the bus bar members.
  • Other portions 601 of the bus bar member protrude from the periphery of the back cover member, which now includes the photovoltaic strips and encapsulant according to a specific embodiment. Further details of the present method and structure are provided throughout the present specification and more particularly below.
  • the photovoltaic strips are arranged respectively on a plurality of optical concentrating elements.
  • Each of the plurality of photovoltaic strips has a strip width and a strip length.
  • Each of the photovoltaic strips is coupling at least one of the plurality of concentrating elements.
  • each of the photovoltaic strips converts light directly into electrical current.
  • each of the photovoltaic strips is made of a material selected from mono-crystalline silicon, poly-crystalline silicon, amorphous silicon copper indium diselenide (CIS), cadmium telluride CdTe, or nanostructured materials.
  • CIS amorphous silicon copper indium diselenide
  • CdTe cadmium telluride
  • FIG. 7 is a simplified diagram 700 illustrating a method of assembling a front cover overlying the assembled back cover, photovoltaic strips, and encapsulant according to an embodiment of the present invention.
  • This diagram is merely an example, which should not unduly limit the scope of the claims herein.
  • the front cover 701 is aligned to the partially assembled back cover and strips according to a specific embodiment.
  • the front cover includes a plurality of concentrating elements 705, which are spatially disposed in parallel to each of the recessed regions and each of the strips.
  • Each of the concentrating elements includes a length disposed along a z-direction according to a specific embodiment. Further details of the front cover including concentrating elements are provided throughout the present specification and more particularly below.
  • the front cover member may be implemented in various ways.
  • the rigid front cover member material can be made of polymer material, glass material, multilayered material, etc.
  • the rigid front cover member is a molded member provided by injection, transfer, compression, or extrusion.
  • the rigid front cover member is characterized by an index of refraction of 1.4 or greater.
  • the rigid front cover member is optically transparent.
  • the rigid front cover member is provided by a light transmission material 88% or greater.
  • the rigid front cover member has light absorption of 4% or less.
  • a cell assembly includes an optical coupling material provided between each of the photovoltaic strips and each of the concentrating elements to optical couple the photovoltaic strip to the concentrating element.
  • the optical coupling material is a liquid (as a starting material), an adhesive, a fluid (e.g., solid, liquid), a film or one or more films, which can be spun on, deposited, coated, evaporated, sprayed, painted, or provided through other suitable techniques.
  • the optical coupling material is characterized by a light transmission of about 88% or greater or 92% or greater; an index of refraction of 1.42 or greater, and a UV stabilizer.
  • the optical coupling material has a suitable index of elasticity, which allows for mechanical and/or thermal variations among the substrates and photovoltaic strips.
  • FIG. 8 is a more detailed diagram illustrating a plurality of concentrating elements on a front cover 701 according to an embodiment of the present invention.
  • This diagram is merely an example, which should not unduly limit the scope of the claims herein.
  • One of ordinary skill in the art would recognize many variations, modifications, and alternatives.
  • each of the concentrating elements for the strip configuration includes a trapezoidal shaped member.
  • Each of the trapezoidal shaped members has a bottom surface coupled to a pyramidal shaped region coupled to an upper region.
  • the upper region is defined by surface 809, which is co-extensive of the front cover.
  • Each of the members is spatially disposed and in parallel to each other according to a specific embodiment.
  • the term "trapezoidal” or “pyramidal” may include embodiments with straight or curved or a combination of straight and curved walls according to embodiments of the present invention.
  • the concentrating elements may be on the front cover, integrated into the front cover, and/or be coupled to the front cover according to embodiments of the present invention. Further details of the front cover with concentrating elements is provided more particularly below.
  • a solar cell apparatus includes a shaped concentrator device operably coupled to each of the plurality of photovoltaic strips.
  • the shaped concentrator device has a first side and a second side.
  • the solar cell apparatus includes an aperture region provided on the first side of the shaped concentrator device.
  • the concentrator device includes a first side region and a second side region.
  • the first side region is characterized by a roughness of about 100 nanometers or 120 nanometers RMS and less
  • the second side region is characterized by a roughness of about 100 nanometers or 120 nanometers RMS and less.
  • the roughness is characterized by a dimension value of about 10% of a light wavelength derived from the aperture regions.
  • the backside member can have a pyramid-type shape.
  • the solar cell apparatus includes an exit region provided on the second side of the shaped concentrator device.
  • the solar cell apparatus includes a geometric concentration characteristic provided by a ratio of the aperture region to the exit region. The ratio can be characterized by a range from about 1.8 to about 4.5.
  • the solar cell apparatus also includes a polymer material characterizing the shaped concentrator device.
  • the solar cell apparatus additionally includes a refractive index of about 1.45 and greater characterizing the polymer material of the shaped concentrator device.
  • the solar cell apparatus includes a coupling material formed overlying each of the plurality of photovoltaic strips and coupling each of the plurality of photovoltaic regions to each of the concentrator devices.
  • the coupling material is characterized by a suitable Young's Modulus.
  • the solar cell apparatus includes a refractive index of about 1.45 and greater characterizing the coupling material coupling each of the plurality of photovoltaic regions to each of the concentrator device.
  • the polymer material is characterized by a thermal expansion constant that is suitable to withstand changes due to thermal expansion of elements of the solar cell apparatus.
  • the plurality of concentrating elements has a light entrance area (Al) and a light exit area (A2) such that A2/A1 is 0.8 and less.
  • the plurality of concentrating elements has a light entrance area (Al) and a light exit area (A2) such that A2/A1 is 0.8 and less, and the plurality of photovoltaic strips are coupled against the light exit area.
  • the ratio of A2/A1 is about 0.5 and less.
  • each of the concentrating elements has a height of 7mm or less.
  • the sealed sandwiched assembly has a width ranging from about 100 millimeters to about 210 millimeters and a length ranging from about 100 millimeters to about 210 millimeters. In a specific embodiment, the sealed sandwiched assembly can even have a length of about 300 millimeters and greater.
  • each of the concentrating elements has a pair of sides. In a specific embodiment, each of the sides has a surface finish of 100 nanometers or less or 120 nanometers and less RMS.
  • FIG. 8A the front cover has been illustrated using a side view 701, which is similar to Figure 8. The front cover also has a top-view illustration 801. A section view 820 from "B-B" has also been illustrated. A detailed view "A" of at least two of the concentrating elements 830 is also shown. Depending upon the embodiment, there can be other variations, modifications, and alternatives.
  • the concentrating elements are made of a suitable material.
  • the concentrating elements can be made of a polymer, glass, or other optically transparent materials, including any combination of these, and the like.
  • the suitable material is preferably environmentally stable and can withstand environmental temperatures, weather, and other "outdoor" conditions.
  • the concentrating elements can also include portions that are coated with an anti-reflective coating for improved efficiency. Coatings can also be used for improving a durability of the concentrating elements.
  • the solar cell apparatus includes a first reflective side provided between a first portion of the aperture region and a first portion of the exit region.
  • the first reflective side includes a first polished surface of a portion of the polymer material.
  • the first reflective side is characterized by a surface roughness of about 120 nanometers RMS and less.
  • the solar cell apparatus includes a second reflective side provided between a second portion of the aperture region and a second portion of the exit region.
  • the second reflective side comprises a second polished surface of a portion of the polymer material.
  • the second reflective side is characterized by a surface roughness of about 120 nanometers and less.
  • the first reflective side and the second reflective side provide for total internal reflection of one or more photons provided from the aperture region.
  • the solar cell apparatus includes a geometric concentration characteristic provided by a ratio of the aperture region to the exit region. The ratio is characterized by a range from about 1.8 to about 4.5.
  • the solar cell apparatus includes a polymer material characterizing the shaped concentrator device, which includes the aperture region, exit region, first reflective side, and second reflective side. As an example, the polymer material is capable of being free from damaged caused by ultraviolet radiation.
  • the solar cell apparatus has a refractive index of about 1.45 and greater characterizing the polymer material of the shaped concentrator device.
  • the solar cell apparatus includes a coupling material formed overlying each of the plurality of photovoltaic strips and coupling each of the plurality of photovoltaic regions to each of the concentrator devices.
  • the solar cell apparatus additionally includes one or more pocket regions facing each of the first reflective side and the second reflective side.
  • the one or more pocket regions can be characterized by a refractive index of about 1 to cause one or more photons from the aperture region to be reflected toward the exit region.
  • FIG. 9 is a simplified diagram illustrating an assembled solar cell structure 900 according to an embodiment of the present invention.
  • the cell structure includes the back cover, plurality of strips, encapsulant, front cover, including concentrator elements, and other features according to a specific embodiment. Portions of bus bars are also exposed for electrical connection to other cells or peripheral circuitry in the solar cell panel or module according to the present invention. Further details of the present solar cell structure can be found throughout the present specification and more particularly below.
  • FIG. 9A various views illustrating the assembled cell structure are provided.
  • the assembled views include a top-view illustration 910, which has various cross-sections including at least "A-A" "B-"B” and "E-E.”
  • the details of A-A 920 are illustrated and run along lengths of the photovoltaic strips.
  • the details of B-B 930 are also illustrated and run normal to the lengths of the photovoltaic strips.
  • An edge portion "C” 940 of the B-B" details is also shown.
  • the edge portion illustrates a recessed region, a photovoltaic strip, encapsulant, and concentrator element corresponding to the photovoltaic strips, among other features.
  • a detail "E-E” 950 along an edge region parallel to one of the bus members is also shown.
  • the present method and resulting device has the back cover coupled to the front cover to form an interface region along a peripheral region or other suitable regions, which contain one or more of the photovoltaic regions composed of photovoltaic materials.
  • coupling occurs using the encapsulant material or other like material or combinations of these elements.
  • the method seals the interface region to form an individual solar cell from the first substrate and the second substrate and places the solar cell in panel assembly.
  • sealing the covers together occurs using a variety of suitable techniques such as ultrasonic welding, vibrational welding, thermal processes, chemical processes, a glue material, an irradiation process (e.g., laser, heat lamp), any combination of these, and others.
  • the sealing technique uses a laser light source called IRAM 200 and 300 manufactured by Branson Ultrasonics Corporation, but can be others. Of course, there can be other variations, modifications and alternatives. Further details of the present method and structure can be found throughout the present specification and more particularly below.
  • the design and efficiency of the present solar cell method and structure occurs using combinations of elements and structures.
  • the present concentrator is bound to the photovoltaic material characteristics according to a specific embodiment.
  • Our present concentrator has achieved a low concentration ratio (e.g., 2 times, 3 times, 4 times) to reduce cost associated with the complexity of high concentrating systems.
  • the low concentration ratio is about 3 times and less for the present concentrating elements for non-tracking solar panel embodiments.
  • the present methods and systems also allow for a non-tracking capability, which leads to reducing cost and increasing reliability according to a specific embodiment.
  • the desirable concentrator contains a low volume of polymers.
  • Low volume is achieved by making the concentrator dimensions as small as possible according to a preferred embodiment to allow for a photovoltaic strip of a determined shape and size that is smaller than conventional photocell structures.
  • the volume of the concentrator is also low to make it lightweight, easy to manufacture, reduce material costs, and allow for handling by human users and/or automation according to a specific embodiment.
  • concentration designs and methods are provided throughout the present specification and more particularly below. That is, one or more of the features below can be incorporated in the present solar cell methods and devices according to embodiments of the present invention.
  • Trough design for non-tracking system to be oriented east to west
  • TIR total internal reflection
  • a concentrator made of a solid material with a high index of refraction for desired TIR
  • Optical concentration ratio is a function of the aperture relative to the exit
  • the concentrator can be made of either glass or polymers
  • the concentrator material must transmit as much light as possible to the photovoltaic material
  • Suggested higher index of refraction material products can be, but not limited to: (1) TopasTM product manufactured by Ticona polymers; (2) CleartufTM product manufactured by M&G polymers; (3) LexanTM product manufactured by GE Advanced
  • Light that enters the concentrator at an angle to the aperture surface will first bend. The amount of bending will be a function of the index of refraction of the concentrator material and the index of refraction of the material outside the concentrator. Then the light will strike the side of the concentrator and if the angle of incidence is greater than the critical angle the light exits the concentrator. This is shown by the orange ray.
  • the present method achieves certain benefits using the present concentrator structure and methods for the solar cell.
  • other features have been incorporated. That is, in a specific embodiment, the following should be true to achieve a total internal reflection condition:
  • the refractive material has a higher indexer of refraction that the incident material, which is on the outside.
  • Air and a vacuum typically has an index of refraction of around one (1).
  • Optical polymers and glass concentrators typically have index of refractions of about one and one half (e.g., 1.48, 1.49, 1.5) or greater.
  • a TER. surface has a very smooth surface finish and remains free of all contaminants such as dust, moisture, finger prints etc.
  • n r is the index of refraction of the refractive material
  • n is the index of refraction of the incident material.
  • the present solar cell and methods should emulate a conventional mono-crystalline silicon based cell as closely as possible. That is, such conventional cells can be those manufactured by SunPower Corp. located at 3939 North First Street, San Jose, California 95134 or other solar cell types such as those manufactured by BP Solar International Inc., Shell Solar, headquartered in The Hague, The Netherlands, Q-CeIIs AG of Germany, SolarWorld AG, Kurt-Schumacher-Str. 12-14, 53113 Bonn/Germany, Sharp Corporation, Osaka, Japan, Kyocera Solar Inc., and others. Alternatively, the solar cells and/or strips can be manufactured using thin film and/or nanotechnology processes.
  • the present solar cell and method has a form, fit, and function that matches certain features of conventional photovoltaic cells.
  • the cell form should be square, as thin as possible (e.g., less than 3 millimeters, less than 7 millimeters), and as light as possible, and have other desirable features.
  • the cell form should be square, as thin as possible (e.g., less than 3 millimeters, less than 7 millimeters), and as light as possible, and have other desirable features.
  • conventional cells are 125 mm 2 and 150 mm 2 . We believe that it is likely that larger cells sizes may be used in the future up to 300 mm 2 . However, for some smaller module applications, smaller cells might be desirable. High voltage, low power modules for battery charging could be one example. 50 mm 2 cells may be desirable for this application. Of course, there can be other variations, modifications, and alternatives.
  • the thickness of the concentrator is a function of the width of the photovoltaic material cell.
  • Narrower cells allow for small exit sizes, smaller apertures, and narrower concentrators.
  • narrower photovoltaic cells often require more cells and handling operations to fill a certain area with cells, which may increase costs.
  • the photovoltaic width could be 0.5mm wide and less depending upon the embodiment.
  • width might not be an issue however the cost can be reduced by fewer handling operations. In this case it is possible that a width up to 3 mm is desirable.
  • the cell uses various photovoltaic strips.
  • the present invention provides a solar cell using a plurality of photovoltaic strips or regions.
  • the photovoltaic strips has one or more of the following characteristics:
  • Thickness of 20 to 100 microns or Thickness of 50 to 400 microns
  • the present invention provides various advantages for solar cells.
  • the present invention provides a cost-effective and energy efficient solution for solar cell systems.
  • the present method and structure provide for packaging of a plurality of photovoltaic strips coupled to respectively plurality of concentrating elements to increase an efficiency of the photovoltaic strips while using less photovoltaic material.
  • the packaged assembly is stand alone and can withstand external forces and/or other environmental conditions according to preferred embodiments.
  • the package is easy to handle and can be used alone or with other packaged cells in a large module, which can string each of the cells in serial and/or parallel configuration according to a specific embodiment.
  • the present package configuration can be changed and designed using selected shapes and sizes, which allow for custom or specialized applications.
  • the present method and structure (including cell and module) uses less material and may be easier to manufacture than conventional solar cell processes.
  • the present invention offers a relative efficiency of about 80% and greater as compared to an original cell in a module. Depending upon the embodiment, one or more of these benefits can be achieved.

Abstract

L'invention se rapporte à une structure de dispositif de cellule solaire et à son procédé de fabrication. Le dispositif comporte un élément de capot arrière, qui comprend une zone de surface et une zone arrière. Le dispositif comprend également une pluralité de régions photovoltaïques disposées de manière à recouvrir la zone de surface de l'élément de capot arrière. Dans un mode de réalisation, la pluralité de régions photovoltaïques occupe une région spatiale photovoltaïque entière. Le dispositif comprend un matériau d'enrobage recouvrant une partie de l'élément de capot arrière et un élément de capot avant couplé au matériau d'enrobage. Une région d'interface est située le long d'au moins une zone périphérique de l'élément de capot arrière et de l'élément de capot avant. Une région hermétique est formée sur au moins la région d'interface de manière à former une cellule solaire individuelle à partir de l'élément de capot arrière et de l'élément de capot avant. Dans un mode de réalisation préféré, la région spatiale photovoltaïque/la zone de surface entière a un rapport d'environ 0.80 et moins par rapport à la cellule solaire individuelle.
PCT/US2006/021803 2005-06-06 2006-06-05 Procede et systeme d'integration d'une cellule solaire au moyen d'une pluralite de regions photovoltaiques WO2006133126A2 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP06760692A EP1902475A2 (fr) 2005-06-06 2006-06-05 Procede et systeme d'integration d'une cellule solaire au moyen d'une pluralite de regions photovoltaiques
JP2008515807A JP2008543111A (ja) 2005-06-06 2006-06-05 複数の光発電領域を用いた集積太陽電池に関する方法およびシステム

Applications Claiming Priority (6)

Application Number Priority Date Filing Date Title
US68807705P 2005-06-06 2005-06-06
US60/688,077 2005-06-06
US11/445,948 2006-06-02
US11/445,933 US20060283495A1 (en) 2005-06-06 2006-06-02 Method and system for integrated solar cell using a plurality of photovoltaic regions
US11/445,948 US20070095386A1 (en) 2005-06-06 2006-06-02 Method and system for integrated solar cell using a plurality of photovoltaic regions
US11/445,933 2006-06-02

Publications (2)

Publication Number Publication Date
WO2006133126A2 true WO2006133126A2 (fr) 2006-12-14
WO2006133126A3 WO2006133126A3 (fr) 2007-11-01

Family

ID=37499021

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2006/021803 WO2006133126A2 (fr) 2005-06-06 2006-06-05 Procede et systeme d'integration d'une cellule solaire au moyen d'une pluralite de regions photovoltaiques

Country Status (4)

Country Link
EP (1) EP1902475A2 (fr)
JP (1) JP2008543111A (fr)
KR (1) KR20080021652A (fr)
WO (1) WO2006133126A2 (fr)

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2007014288A2 (fr) * 2005-07-26 2007-02-01 Solaria Corporation Procede et systeme de fabrication de panneaux solaires mettant en oeuvre une cellule solaire integree mettant en oeuvre plusieurs regions photovoltaiques
WO2010061089A2 (fr) 2008-11-03 2010-06-03 Saint-Gobain Glass France Vitrage a zones concentrant la lumiere par echange ionique
US7910035B2 (en) 2007-12-12 2011-03-22 Solaria Corporation Method and system for manufacturing integrated molded concentrator photovoltaic device
US7910822B1 (en) 2005-10-17 2011-03-22 Solaria Corporation Fabrication process for photovoltaic cell
US7910392B2 (en) 2007-04-02 2011-03-22 Solaria Corporation Method and system for assembling a solar cell package
US8119902B2 (en) 2007-05-21 2012-02-21 Solaria Corporation Concentrating module and method of manufacture for photovoltaic strips
CN101681950B (zh) * 2007-05-31 2012-06-20 法国圣戈班玻璃厂 获得用于光伏板的纹理化基板的方法
US8227688B1 (en) 2005-10-17 2012-07-24 Solaria Corporation Method and resulting structure for assembling photovoltaic regions onto lead frame members for integration on concentrating elements for solar cells

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2014067925A (ja) * 2012-09-26 2014-04-17 Toshiba Corp 太陽電池モジュール

Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3700714A (en) * 1971-06-24 1972-10-24 Stephen B Hamilton Curable compositions
US4029519A (en) * 1976-03-19 1977-06-14 The United States Of America As Represented By The United States Energy Research And Development Administration Solar collector having a solid transmission medium
US4097308A (en) * 1977-04-28 1978-06-27 Tideland Signal Corporation Glass enclosed solar cell panel
US4118249A (en) * 1977-08-30 1978-10-03 The United States Of America As Represented By The United States Department Of Energy Modular assembly of a photovoltaic solar energy receiver
US4170507A (en) * 1977-12-27 1979-10-09 Motorola, Inc. Method for encapsulating a solar cell array
US4683154A (en) * 1985-08-19 1987-07-28 The United States Of America As Represented By The United States Department Of Energy Laser sealed vacuum insulation window
US5118361A (en) * 1990-05-21 1992-06-02 The Boeing Company Terrestrial concentrator solar cell module
JPH0918031A (ja) * 1995-06-30 1997-01-17 Sanyo Electric Co Ltd 太陽電池とその製造方法
US5707459A (en) * 1993-06-24 1998-01-13 Canon Kabushiki Kaisha Solar cell module provided with a heat-fused portion
US20030121542A1 (en) * 2000-03-30 2003-07-03 Wolfgang Harneit Method for producing a solar module with thin-film solar cells which are series-connected in an integrated manner and solar modules produced according to the method, especially using concentrator modules
US20040123895A1 (en) * 2002-10-22 2004-07-01 Sunray Technologies, Inc. Diffractive structures for the redirection and concentration of optical radiation

Patent Citations (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3700714A (en) * 1971-06-24 1972-10-24 Stephen B Hamilton Curable compositions
US4029519A (en) * 1976-03-19 1977-06-14 The United States Of America As Represented By The United States Energy Research And Development Administration Solar collector having a solid transmission medium
US4097308A (en) * 1977-04-28 1978-06-27 Tideland Signal Corporation Glass enclosed solar cell panel
US4118249A (en) * 1977-08-30 1978-10-03 The United States Of America As Represented By The United States Department Of Energy Modular assembly of a photovoltaic solar energy receiver
US4170507A (en) * 1977-12-27 1979-10-09 Motorola, Inc. Method for encapsulating a solar cell array
US4683154A (en) * 1985-08-19 1987-07-28 The United States Of America As Represented By The United States Department Of Energy Laser sealed vacuum insulation window
US5118361A (en) * 1990-05-21 1992-06-02 The Boeing Company Terrestrial concentrator solar cell module
US5707459A (en) * 1993-06-24 1998-01-13 Canon Kabushiki Kaisha Solar cell module provided with a heat-fused portion
JPH0918031A (ja) * 1995-06-30 1997-01-17 Sanyo Electric Co Ltd 太陽電池とその製造方法
US20030121542A1 (en) * 2000-03-30 2003-07-03 Wolfgang Harneit Method for producing a solar module with thin-film solar cells which are series-connected in an integrated manner and solar modules produced according to the method, especially using concentrator modules
US20040123895A1 (en) * 2002-10-22 2004-07-01 Sunray Technologies, Inc. Diffractive structures for the redirection and concentration of optical radiation

Non-Patent Citations (2)

* Cited by examiner, † Cited by third party
Title
BOEDEKER PLASTICS INC.: 'Acrylic Polymethyl-MethAcrylate PMMA datasheet', [Online] 07 May 1999, XP008135646 Retrieved from the Internet: <URL:http://www.boedeker.com/acryl_p.hmt> *
'Solar Electricity Beginner's notes', [Online] 18 January 2004, XP008124297 Retrieved from the Internet: <URL:http://www.sunwindsolar.com/a_lessons/solar_beginners_notes.html> *

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2007014288A2 (fr) * 2005-07-26 2007-02-01 Solaria Corporation Procede et systeme de fabrication de panneaux solaires mettant en oeuvre une cellule solaire integree mettant en oeuvre plusieurs regions photovoltaiques
WO2007014288A3 (fr) * 2005-07-26 2009-04-30 Solaria Corp Procede et systeme de fabrication de panneaux solaires mettant en oeuvre une cellule solaire integree mettant en oeuvre plusieurs regions photovoltaiques
US7910822B1 (en) 2005-10-17 2011-03-22 Solaria Corporation Fabrication process for photovoltaic cell
US8227688B1 (en) 2005-10-17 2012-07-24 Solaria Corporation Method and resulting structure for assembling photovoltaic regions onto lead frame members for integration on concentrating elements for solar cells
US7910392B2 (en) 2007-04-02 2011-03-22 Solaria Corporation Method and system for assembling a solar cell package
US8119902B2 (en) 2007-05-21 2012-02-21 Solaria Corporation Concentrating module and method of manufacture for photovoltaic strips
CN101681950B (zh) * 2007-05-31 2012-06-20 法国圣戈班玻璃厂 获得用于光伏板的纹理化基板的方法
US7910035B2 (en) 2007-12-12 2011-03-22 Solaria Corporation Method and system for manufacturing integrated molded concentrator photovoltaic device
WO2010061089A2 (fr) 2008-11-03 2010-06-03 Saint-Gobain Glass France Vitrage a zones concentrant la lumiere par echange ionique

Also Published As

Publication number Publication date
WO2006133126A3 (fr) 2007-11-01
JP2008543111A (ja) 2008-11-27
KR20080021652A (ko) 2008-03-07
EP1902475A2 (fr) 2008-03-26

Similar Documents

Publication Publication Date Title
US20120234390A1 (en) Method and system for integrated solar cell using a plurality of photovoltaic regions
CN202930413U (zh) 太阳能模组装置
US20070056626A1 (en) Method and system for assembling a solar cell using a plurality of photovoltaic regions
US8242351B2 (en) Solar cell structure including a plurality of concentrator elements with a notch design and predetermined radii and method
US20080235949A1 (en) Method and system for manufacturing solar panels using an integrated solar cell using a plurality of photovoltaic regions
EP1902475A2 (fr) Procede et systeme d&#39;integration d&#39;une cellule solaire au moyen d&#39;une pluralite de regions photovoltaiques
US8049098B2 (en) Notch structure for concentrating module and method of manufacture using photovoltaic strips
US7910392B2 (en) Method and system for assembling a solar cell package
US20120295388A1 (en) Large area concentrator lens structure and method
KR101181547B1 (ko) 광 집속형 태양전지 모듈 및 그의 어셈블리 방법
US7910035B2 (en) Method and system for manufacturing integrated molded concentrator photovoltaic device
US20090188563A1 (en) Solar Cell Structure Including A Plurality of Concentrator Elements With A Notch Design and Predetermined Radii and Method
US20100282316A1 (en) Solar Cell Concentrator Structure Including A Plurality of Glass Concentrator Elements With A Notch Design
US20090151770A1 (en) Method and material for coupling solar concentrators and photovoltaic devices
WO2008122047A1 (fr) Structure de cellule photovoltaïque comprenant une pluralité de concentrateurs à encoches et rayon défini, et procédé correspondant
CN101548393A (zh) 通过使用多个光电区的集成式太阳能电池对太阳电池板进行制造的方法及系统
US8227688B1 (en) Method and resulting structure for assembling photovoltaic regions onto lead frame members for integration on concentrating elements for solar cells
US8168884B2 (en) Solar cell structure including a plurality of concentrator elements with a notch design and predetermined radii and method
US8173890B2 (en) Solar cell structure including a plurality of concentrator elements with a notch design and predetermined RADII and method
US20080236651A1 (en) Solar cell concentrator structure including a plurality of concentrator elements with a notch design and method having a predetermined efficiency
US20110017264A1 (en) Thermal management method and device for solar concentrator systems

Legal Events

Date Code Title Description
WWE Wipo information: entry into national phase

Ref document number: 200680020047.8

Country of ref document: CN

WWE Wipo information: entry into national phase

Ref document number: 8000/DELNP/2006

Country of ref document: IN

121 Ep: the epo has been informed by wipo that ep was designated in this application
WWE Wipo information: entry into national phase

Ref document number: 12007501911

Country of ref document: PH

ENP Entry into the national phase

Ref document number: 2008515807

Country of ref document: JP

Kind code of ref document: A

NENP Non-entry into the national phase

Ref country code: DE

WWE Wipo information: entry into national phase

Ref document number: 1020077028873

Country of ref document: KR

WWE Wipo information: entry into national phase

Ref document number: 2006760692

Country of ref document: EP