WO2014037722A1 - Module cellulaire photovoltaïque concentré (cpv) à élément optique secondaire, et procédé de fabrication - Google Patents

Module cellulaire photovoltaïque concentré (cpv) à élément optique secondaire, et procédé de fabrication Download PDF

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Publication number
WO2014037722A1
WO2014037722A1 PCT/GB2013/052321 GB2013052321W WO2014037722A1 WO 2014037722 A1 WO2014037722 A1 WO 2014037722A1 GB 2013052321 W GB2013052321 W GB 2013052321W WO 2014037722 A1 WO2014037722 A1 WO 2014037722A1
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WO
WIPO (PCT)
Prior art keywords
cpv
photovoltaic cell
photovoltaic
cell
layer
Prior art date
Application number
PCT/GB2013/052321
Other languages
English (en)
Inventor
Geoffrey Duggan
Original Assignee
Fullsun Photovoltaics Limited
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
Application filed by Fullsun Photovoltaics Limited filed Critical Fullsun Photovoltaics Limited
Publication of WO2014037722A1 publication Critical patent/WO2014037722A1/fr

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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
    • 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
    • H01L31/04—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
    • 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
    • H01L31/052—Cooling means directly associated or integrated with the PV cell, e.g. integrated Peltier elements for active cooling or heat sinks directly associated with the 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
    • 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 to the manufacture and use of a secondary optical element in a concentrated photovoltaic cell arrangement.
  • the architecture permits rapid assembly of a photovoltaic chip carrier onto a backplane using high speed pick and place (PnP) tools.
  • PnP pick and place
  • PV Solar photovoltaic
  • multicrystalline silicon organic materials like dyes and finally inorganic III- V, semiconductor materials.
  • Concentrated PV is a variation of solar PV technology which seeks to replace the large areas of semiconductor or thin-film materials by small areas of the more expensive, highly efficient III-V cells in combination with cheap plastic or glass Fresnel lenses or mirrors that concentrate the Sun's intensity several hundred times onto the cell .
  • CPV modules or panels are mounted on a tracking system that keeps the focus of the Sun on the cell as it moves through the sky during the day.
  • a complete CPV system can be broken down into a number of sub-units:
  • III-V PV cells • III-V PV cells, receivers, lenses or mirrors which are assembled into modules - to concentrate the sun's rays and generate the direct current (DC)
  • Inverters - to convert the DC to an alternating current (AC) and feed the current into the grid
  • CPV modules are constructed either using mirrors - a reflective system - or lenses - a refractive system .
  • the main elements and technical challenges that need to be addressed in designing and constructing a CPV module are illustrated by reference to point focus reflective and refractive systems shown in Figure 1.
  • the reflective system shown above uses a primary concave mirror (1) and a convex secondary mirror (2), with the light from the sun being focused through an optical rod (3) onto the solar cell (4), again mounted onto a suitable heatsink.
  • This optical rod performs the same function as the SOE in the refractive system .
  • the PV cell together with a silicon bypass or protection diode, PCB heatsink and SOE form a, so called, receiver (Rx) unit.
  • the Rx is the power generator of the CPV system so its design, performance and reliability are one of the keys to building an efficient and economic system. Most manufacturers of CPV systems today use a SOE in their Rx design.
  • a CPV module consists of an array of series connected Rx which have been mounted on the base of the module at the focus of either a parquet of Fresnel lenses or suitable reflective optics. Each module has to be mounted and accurately aligned on the dual axis sun tracker.
  • Today's CPV technology aims to concentrate the sun anywhere between 300x and lOOOx.
  • the geometric concentration factor is defined as the ratio between the area of the collection (Fresnel) lens and the illuminated area of the PV cell .
  • these systems are designed around the use of PV cells that are, for example, 10mm x 10mm or 5.5mm x 5.5mm. This implies that for example, a 625x system has to have lenses that are larger than the cell by 25x in each planar direction. With such large lenses it is difficult to focus the sun's rays efficiently without the focal length of the lens being long; typically the z-dimension would be 1.5x to 3x the x-y dimension of the lens.
  • This invention seeks to address the shortcomings of the current CPV module designs by:
  • Utilizing small PV cells means that Fresnel lenses with a short focal length can be used to focus light onto individual Rx; thus ensuring that the CPV module has a "low profile" which minimizes the use of materials and provides a beneficial profile for wind resistance;
  • a Concentrated Photovoltaic (CPV) module comprising an array of
  • photovoltaic cells connected to a patterned conductive backplane electrically connecting the array of photovoltaic cells together; a photovoltaic cell being arranged to receive light via a primary optical element, eg., a Fresnel lens, and a secondary optical element mounted over the photovoltaic cell, wherein the secondary optical element is a moulded lens containing an optically transparent lens material disposed over the photovoltaic cell.
  • a primary optical element eg., a Fresnel lens
  • secondary optical element mounted over the photovoltaic cell, wherein the secondary optical element is a moulded lens containing an optically transparent lens material disposed over the photovoltaic cell.
  • the secondary optical element is an aspheric lens and silicone is preferred as a transparent lens material.
  • the patterned conductive backplane comprises a heat sink layer, insulating layer, a conductive layer and a resist layer such that the photovoltaic cell is connected to the conductive layer through exposed regions in the resist layer.
  • the conductive layer is a patterned metal interconnect layer and preferably the photovoltaic cell is bonded, by being soldered or epoxy bonded, to exposed regions on the patterned metal interconnect layer.
  • the resist layer is deposited over the conductive layer and more preferably the heat sink layer is affixed to the back of the insulating layer.
  • the heat sink layer incorporates metallic fins and in a preferred embodiment the insulating layer comprises a dielectric.
  • a method of forming a photovoltaic cell carrier comprising mounting a photovoltaic cell; placing a mould over the photovoltaic cell; and filling the mould with an optically transparent lens material disposed over the photovoltaic cell.
  • the method includes picking a photovoltaic cell carrier as defined above and placing the photovoltaic cell carrier onto a patterned conductive backplane; and joining the photovoltaic cell carrier to the patterned conductive backplane.
  • Figure 1 represents schematic illustrations of point-focus reflective and refractive CPV optical systems
  • Figure 2a is cross section of an overmoulded photovoltaic leadless chip package, also known as a receiver (Rx);
  • Figure 2b illustrates the way in which the PV cell is connected to the Cu leadframe portion of the Rx
  • Figure 3 is a schematic diagram of how the Rx are soldered to the IMS baseplate
  • Figure 4 is a schematic diagram showing the functionality of the Fresnel lens parquet and its relation to the Rx arranged on the IMS baseplate;
  • Figures 5a-c are schematic diagrams in cross section of the CPV module showing the lens support and details showing the way in which one embodiment of the invention seals the module against water and dust ingress;
  • Figures 6a-b are schematic diagrams of a circuit layout that connects the PV cell and reverse biased bypass diode silicon diode in parallel on the IMS backplane and an example of how an array of Rx and bypass diodes could be arranged in parallel strings on the IMS backplane.
  • the solder resist layer has been omitted for clarity
  • Figure 7 is a schematic diagram of Rx and bypass diodes together with an IC chip that is capable of performing local maximum power point tracking;
  • Figure 8 is a schematic diagram of Rx and bypass diodes together with an IC chip that is capable of performing local DC to AC conversion. Again, the solder resist layer has been omitted in both these diagrams.
  • the preferred CPV module is made from the following component parts
  • a receiver having :
  • a PV cell - preferably a high efficiency, III-V multi-junction cell that has an optical aperture of ⁇ 1.5mm x 1.5mm;
  • a leadless chip package in which the PV cell is die attached to a metallic leadframe by a suitable electrically conductive solder or epoxy; c.
  • POE primary optical element
  • the SOE is preferably produced by overmoulding the silicone lens onto the PV cell and leadframe or chip carrier which results in a simplified packaging process that simultaneously protects the PV cell and that is small enough to be assembled onto the CPV module's backplane using high speed pick and place (PnP) tools readily available from the optoelectronics and in particular the high brightness LED industry.
  • a metal cored printed circuit board that forms the baseplate of the CPV module and which can be patterned with electronic circuitry that allows series and parallel connections of receivers and bypass, protection diodes.
  • Receivers are placed into position on the PCB and subsequently re- flow soldered to allow electrical connections and final positioning.
  • a matrix of Fresnel lenses often referred to as a parquet, that is positioned at a predetermined vertical position relative to the PCB
  • FIG. 2a illustrates a cross section through a leadless chip package 200 into which has been attached a multi-junction photovoltaic (PV) cell (4).
  • PV photovoltaic
  • the PV cell (4) has wire bonds (7) attached to its upper surface to complete the electrical circuit and the open package is then placed into an appropriate mould, the inner surface of which has been highly polished in the shape of an aspheric lens (6) to focus incident light onto the optical aperture of the PV cell.
  • the mould is then filled with an optically clear silicone, for example, which once cured completely
  • Figure 2b shows how the PV cell is mounted and bonded to the two sections of the Cu pads that are an integral part of the package.
  • the package is made rigid by the simultaneous moulding of sides and base that separates the two Cu connector pads.
  • the entire package is made from a material able to withstand high temperatures whilst also being resistant to damage by intense levels of UV, candidate materials would be, but not limited to, a silicone.
  • the sides of the package would be first moulded in a material able to withstand high temperatures and intense levels of UV, such as a liquid crystal polymer (LCP) or even a metal,
  • the transparent silicone lens would be overmoulded, simultaneously filling the open cavity, encasing the PV cell and forming the lens to focus the light from the primary optical element - the Fresnel lens or similar.
  • Figure 3 shows a cross section of two moulded packages that have been soldered 9 to pads 11 that form part of the electronic circuitry that has been patterned onto a MCPCB 10 or IMS.
  • the Rx packages 200 are picked and placed accurately and at high speed onto exposed features on the PCB (10) that are defined by openings in the solder resist layer 12.
  • the whole PCB would then be placed into a standard re-flow oven to melt the solder to ensure electrical contact with the circuitry on the PCB and hold the PV cells accurately in place.
  • the PV cell 4 can be mounted directly upon pads 11 without the base of a PV cell being first soldered to a metallic leadframe 8.
  • the PV cell is soldered to one pad 11 and is wire bonded from its upper surface to an adjacent pad to complete the electrical circuit.
  • Figure 4 shows us in cross section how the array of receivers are positioned relative to a parquet 14 of Fresnel lenses whose centres are positioned such that parallel light from the Sun's rays are focussed to a position either at the apex of the silicone lens or just inside its body.
  • the lens parquet could be made from PMMA for example or of a thin layer of silicone that is laminated to a suitable glass - a so-called Silicone-on-glass (SOG) lens.
  • Figure 5a is a cross section of the assembled module where the lens parquet 14 is held in place by a support structure 16.
  • the support structure would be typically aluminium; it could however be any material that is rigid enough to support the lens and will not deteriorate over more than twenty years exposure of extremes of temperature a prolonged exposure to UV. It should also be able to withstand high concentrations of sunlight should the tracker malfunction and an "off axis" beam be directed toward the support structure.
  • Figures 5b and 5c show detail of how the support structure is attached to the base of the module and the lens parquet.
  • a thin, continuous bead of an appropriate silicone adhesive (15) is sandwiched between the parts to be joined and then cured once in place.
  • a bead of silicone sealant but other materials such as 3M VHB tape (or equivalent) might also be used.
  • Figure 6a shows an example of how the Rx 200 and silicon bypass diode (19) can be connected in parallel on the IMS baseplate with the Rx 200 and bypass diodes reflow soldered to pads 18, 20 opened up on the IMS
  • Figure 6b shows one example of the way in which the Rx 200 and silicon bypass diodes are arranged on the IMS baseplate.
  • the Rx 200 are arranged in parallel strings so as to optimise the voltage and current being delivered from each individual module to either a central inverter or a micro-inverter that is sited within the module.
  • Figure 7 shows an example of how the Rx 200 can be connected on the PCB together with an integrated circuit or set of microchips 21 that can locally optimise the maximum power point tracking (MPPT) of each individual module on a distributed array which will significantly increase the overall power generated compared to an array with just a central inverter.
  • MPPT maximum power point tracking
  • Figure 8 shows an example of how the Rx 200 can be easily connected to an integrated circuit or chip set 22 that will allow each individual module to convert the local DC to AC without the need of a central, expensive and potentially unreliable inverter.

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  • Physics & Mathematics (AREA)
  • Condensed Matter Physics & Semiconductors (AREA)
  • Electromagnetism (AREA)
  • General Physics & Mathematics (AREA)
  • Engineering & Computer Science (AREA)
  • Computer Hardware Design (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Power Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Sustainable Development (AREA)
  • Photovoltaic Devices (AREA)

Abstract

Module photovoltaïque concentré (CPV) comprenant un réseau de cellules photovoltaïques connectées à un fond de panier conducteur à motifs reliant électriquement les cellules photovoltaïques du réseau les unes aux autres; une cellule photovoltaïque étant agencée pour recevoir de la lumière par l'intermédiaire d'un élément optique primaire, par exemple, une lentille de Fresnel, et d'un second élément optique monté au-dessus de la cellule photovoltaïque, le second élément optique étant une lentille moulée contenant un matériau de lentille optiquement transparent disposé sur la cellule photovoltaïque.
PCT/GB2013/052321 2012-09-05 2013-09-05 Module cellulaire photovoltaïque concentré (cpv) à élément optique secondaire, et procédé de fabrication WO2014037722A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB1215844.0 2012-09-05
GBGB1215844.0A GB201215844D0 (en) 2012-09-05 2012-09-05 Concentated photovoltaic (CPV) cell module with secondary optical element and method of fabrication

Publications (1)

Publication Number Publication Date
WO2014037722A1 true WO2014037722A1 (fr) 2014-03-13

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WO (1) WO2014037722A1 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
RU2578735C1 (ru) * 2014-12-10 2016-03-27 Федеральное государственное бюджетное учреждение науки Физико-технический институт им. А.Ф. Иоффе Российской академии наук Концентраторный солнечный фотоэлектрический модуль
EP3483942A4 (fr) * 2016-07-07 2020-01-08 Sumitomo Electric Industries, Ltd. Module de génération électrique photovoltaïque à concentrateur, dispositif de génération électrique photovoltaïque à concentrateur, et système de purification d'hydrogène

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN112466860B (zh) * 2020-11-26 2023-09-22 厦门路泽光电科技有限公司 一种led灯板成型制作方法

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1835547A1 (fr) * 2004-11-01 2007-09-19 Zhores Ivanovich Alferov Module photovoltaique
US20070256726A1 (en) * 2006-05-05 2007-11-08 Palo Alto Research Center Incorporated Laminated Solar Concentrating Photovoltaic Device
US20080185034A1 (en) * 2007-02-01 2008-08-07 Corio Ronald P Fly's Eye Lens Short Focal Length Solar Concentrator
US20100319773A1 (en) * 2009-06-22 2010-12-23 Solarmation, Inc. Optics for Concentrated Photovoltaic Cell

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1835547A1 (fr) * 2004-11-01 2007-09-19 Zhores Ivanovich Alferov Module photovoltaique
US20070256726A1 (en) * 2006-05-05 2007-11-08 Palo Alto Research Center Incorporated Laminated Solar Concentrating Photovoltaic Device
US20080185034A1 (en) * 2007-02-01 2008-08-07 Corio Ronald P Fly's Eye Lens Short Focal Length Solar Concentrator
US20100319773A1 (en) * 2009-06-22 2010-12-23 Solarmation, Inc. Optics for Concentrated Photovoltaic Cell

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
RU2578735C1 (ru) * 2014-12-10 2016-03-27 Федеральное государственное бюджетное учреждение науки Физико-технический институт им. А.Ф. Иоффе Российской академии наук Концентраторный солнечный фотоэлектрический модуль
EP3483942A4 (fr) * 2016-07-07 2020-01-08 Sumitomo Electric Industries, Ltd. Module de génération électrique photovoltaïque à concentrateur, dispositif de génération électrique photovoltaïque à concentrateur, et système de purification d'hydrogène
US10818810B2 (en) 2016-07-07 2020-10-27 Sumitomo Electric Industries, Ltd. Concentrator photovoltaic module, concentrator photovoltaic device, and hydrogen generating system

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Publication number Publication date
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