CN104052389B - 具有固态光学元件的聚光型太阳能收集器 - Google Patents
具有固态光学元件的聚光型太阳能收集器 Download PDFInfo
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Abstract
一种卡塞格林(Cassegrain)型聚光型太阳能收集器电池,包括设置在透光(例如玻璃)光学元件的相对凸面和凹面上的主镜和次镜。光进入围绕着次镜的孔内,并被主镜朝着次镜反射,次镜将该光再次反射到光伏电池上,该光伏电池安装在由凸面环绕的中央区域上。主镜和次镜优选地形成为直接沉积或电镀在光学元件上的镜面膜。聚光型太阳能收集器阵列包括片状的光学面板,该光学面板包括排列成行的多个光学元件。光伏电池直接安装在光学面板上,各个收集器电池的主镜包括金属膜片段,这些金属膜片段由光伏电池耦合起来,以促进所产生的电能进行传输。旁路二极管与光伏电池并联连接。
Description
本申请是申请人帕洛阿尔托研究中心公司于
2006
年
4
月
18
日提交的同名中国专利申请
2006100770223
的分案申请。
技术领域
本发明涉及太阳能发生器,具体地,本发明涉及聚光型太阳能收集器。
背景技术
用来产生电能的光伏太阳能收集设备通常包括平板收集器和聚光型太阳能收集器。平板收集器通常包括光伏电池阵列和形成在半导体(例如,单晶硅或多晶硅)基板上的相联电子设备,由于从平板收集器输出的电能是阵列面积的正函数,因此需要很大、很昂贵的半导体基板。聚光型太阳能收集器通过采用例如抛物面反射器或能够聚焦光束的透镜聚集光束(即太阳光线),产生强度更高的太阳能光束,而后又将太阳能光束引导到很小的光伏电池上,从而降低了对大半导体基板的需求。因此,聚光型太阳能收集器比起平板收集器的优点在于它们所使用的半导体的量少得多,另一个优点在于能够更加有效地产生电能。
传统的聚光型太阳能收集器存在的问题在于制造、操作和维护起来很昂贵。在传统的收集器中使用的用以聚焦光束的反射器和/或透镜是分别制造的,因此必需很费力地进行装配,以在聚焦的光束和光伏电池之间提供正确的对准。另外,随着时间的流逝,反射器和/或透镜可能由于热循环或振动而变得不再对准,而且可能由于暴露于环境而变得很脏。从而,形式为清洁和调节反射器/透镜的维护就变得非常重要,特别当反射器/透镜制造成很难清洁的不平坦形状时。
因此,需要一种能够避免与传统聚光型
PV
电池相关联的昂贵装配以及维护费用的聚光器型
PV
电池及阵列。
发明内容
本发明涉及一种有效的卡塞格林(
Cassegrain
)型聚光型太阳能收集器,该聚光型太阳能收集器通过在粘附于固态透光(例如玻璃)光学元件相对内表面上的主镜与次镜之间反射光,将光收集(例如,聚焦或者以其他方式会聚)到光伏电池上。光学元件包括相对较大的凸面(突起)下表面和上表面,该上表面包括平坦的孔和设在该孔中心处的相对较小凹面(弯曲)表面(例如,凹陷)。主镜和次镜被设置得使反射面面对着光学元件。在一个实施例中,凸面和凹面是相联的锥形(例如,双曲线和/或抛物线)表面,这些锥形表面设置得使穿过孔到达主镜任何点上的光被反射到次镜的相应点上,次镜又再次向主镜的顶点反射该光,光伏电池安装在该顶点处以将光转换成电能。因为光学元件是固态的(即,因为凸面和凹面相对于彼此保持固定),所以主镜和次镜保持着永久地对准,从而维持着最佳的光学操作同时使维护成本最低。而且,在气体/固体界面处的损耗最低,这是因为只有固态光学元件材料(例如,低铁玻璃)定位在主镜与次镜之间。
依照本发明的一个实施例,主镜和次镜是分别直接形成(例如,沉积或电镀)在光学元件的凸面和凹面上的薄膜。通过仔细地模制光学元件使之包括具有期望形状和定位的凸面和凹面,主镜和次镜当形成为镜面材料膜时基本上是自形成和自对准的,从而大大简化了制造过程而且将制造成本降至最低。将主镜和次镜直接形成在光学元件上还有利于用相同的镜面材料(例如银)同时低成本地电镀两个镜面,从而进一步降低了制造成本。
依照本发明的另一个实施例,光学元件被用来作为底板结构,用于支撑光伏电池和相关联的导体,这些相关联的导体串行地电学连接多个光伏电池以形成收集器阵列,从而消除了对单独的印刷电路板的需求,因此降低了制造成本。
依照本发明的另一个实施例,主镜包括两个或多个金属膜部分,这些金属膜部分设置在凸面的不同区域上并被一个或多个窄间隙隔开。采用两个或多个隔开的金属膜部分形成主镜有利于将主镜用作导电通路,从而将聚光型太阳能收集器阵列内相邻收集器的光伏电池电链接起来。在一个实施例中,每个主镜包括两半金属膜,它们被穿过凸面环绕着的中央区域的间隙分开,相邻的半金属膜由安装在中央区域上的光伏电池链接。相关联的旁路晶体管与每个光伏电池串联连接,以避免由于光伏电池故障引起的阵列故障。
依照本发明的另一个实施例,在每个光伏电池上设置散热器,以促进热量从电池转移到相邻主镜部分,由此降低对有源或无源冷却的需求。
依照本发明的另一个实施例,使用高速取放(
pick-and-place
)设备将光伏电池和其他的部件(例如,旁路二极管和散热器)表面安装到平坦化的中央区域上。在光伏电池与定位在该平坦的中央区域上的主镜膜的下面部分之间设置可选的介电层(例如,焊料掩模),以促进正确的电学连接。
依照本发明的另一个实施例,次镜上覆盖密封剂结构,该密封剂结构的平坦上表面与开孔表面共面,从而提供具有易于清洁的平坦表面的阵列,由此降低维护成本。另外,该密封剂结构保护着次镜免受侵蚀。
附图说明
参看下面的说明、所附的权利要求以及附图,本发明的这些和其他特征、方面以及优点将可以更好地理解,在附图中:
图
1
是示出依照本发明一个实施例的聚光型太阳能收集器电池的分解透视图;
图
2
是示出图
1
的聚光型太阳能收集器电池在工作期间的侧视图;
图
3
是示出依照本发明另一个实施例的聚光型太阳能收集器电池的分解透视图;
图
4
是示出图
3
的聚光型太阳能收集器电池的底部透视图;
图
5
是示出依照本发明另一个实施例的光学面板的透视图;
图
6
是示出依照本发明另一个实施例、包括图
5
的光学面板的聚光型太阳能收集器阵列的简化侧视图;
图
7
是详细示出图
6
的阵列的聚光型太阳能收集器电池的横截面侧视图;
图
8
(
A
)、
8
(
B
)以及
8
(
C
)是示出依照本发明另一个实施例将光伏电池和旁路二极管安装在图
7
的聚光型太阳能收集器电池上的方法的放大、背部透视图;
图
9
是示出依照本发明的另一个实施例的聚光型太阳能收集器阵列的背部透视图;
图
10
是示出包括图
9
的聚光型太阳能收集器阵列的太阳能收集器装置的简化平面图。
具体实施方式
图
1
是显示依照本发明一个实施例的内反射镜、卡塞格林型聚光型太阳能收集器
100
的分解透视图。聚光型太阳能收集器
100
通常包括光学元件
110
,光伏电池
120
,主镜
130
和次镜
140
。光学元件
110
是固态盘状的透光结构,包括上层
111
、从上层
111
下侧突出的相对较大的凸面
112
、设在上层
111
上侧的基本平坦的开孔表面
115
、以及在开孔表面
115
内规定的相对较小的凹(曲)面(凹陷)
117
(即,延伸到上层
111
内)。为了将材料、重量、厚度和光吸收减至最少,上层
111
可以近乎为零地小。次镜
140
的凹度可以延伸超过上层
111
的厚度。光伏电池
120
定位在中央区域
113
内,该中央区域
113
位于凸面
112
的中央并被凸面
112
环绕着。主镜
130
设置在凸面
112
上,次镜
140
设置在凹面
117
上。主镜
130
和次镜
140
的形状和设置使得穿过开孔表面
115
的特定区域进入光学元件
110
内、沿着预定方向(例如垂直于开孔表面
115
)传播的光束(线)被主镜
130
的对应区域反射到次镜
140
相联区域,并从次镜
140
的相联区域反射到光伏电池
120
(例如,直接或者借助于安置在次镜和光伏电池
120
之间的反射或折射表面,从次镜
140
反射到光伏电池
120
),这将在下面进行更详细的描述。如此处所用的,方向术语“上部的”、“下部的”、“上方”以及“下方”旨在为说明的目的提供相对的位置,并不旨在指定绝对的参考系。
依照本发明的一个实施例,主镜
130
和次镜
140
通过直接在凸面
112
和凹面
117
上溅射或者以其他方式沉积反射镜材料(例如,银(
Ag
)或铝(
Al
))而制成,从而使制造成本减至最小并且能提供优良的光学性质。通过采用已知的镜面制作技术在凸面
112
和凹面
117
上溅射或者以其他方式形成镜面膜,主镜
130
基本上成凸面
112
的形状,次镜
140
基本上成凹面
117
的形状。这样,光学元件
110
被模制或者以其他方式制作,使得凸面
112
和凹面
117
被设置和整形成产生期望的镜面形状。应当注意,通过形成具有期望镜面形状和位置的凸面
112
和凹面
117
,主镜
130
和次镜
140
有效地自形成和自对准,从而消除了与传统聚光型太阳能收集器相联的昂贵的装配和对准成本。另外,因为主镜
130
和次镜
140
保持固定在光学元件
110
上,它们的相对位置永久设定,由此消除了对调整和重新对准的需要,而这些在传统的多部件设置中都是需要的。在一个实施例中,主镜
130
和次镜
140
用相同的(同样的)一种材料或多种材料(例如,电镀的
Ag
)同时形成,从而使制作成本降至最低。另外,通过利用光学元件
110
的表面制作反射镜,一旦光通过开孔表面
115
进入光学元件
110
,光在到达光伏电池
120
之前仅被主镜
130
/凸面
112
和次镜
140
/凹面
117
反射。这样,该光经历仅仅一次空气/玻璃界面(即,开孔表面
115
),从而将传统的多部件聚光型太阳能收集器所具有的损耗降至最小。通过在开孔表面
115
上采用抗反射涂层,该单个空气/玻璃界面的损耗可以进一步降低。虽然也可以分开形成主镜
130
和次镜
140
,然后将这些反射镜分别粘附在凸面
112
和凹面
117
上,但是这种制造方法会大大增加制造成本,而且可能会降低直接在凸面
112
和凹面
117
上形成反射镜膜所提供的优良的光学性能。
在一个具体实施例中,根据一种已知的玻璃模制法用低铁玻璃(例如,由
Pilkington PLC, UK
制造的光学白玻璃)结构模制出光学元件
110
。模制的低铁玻璃同其它的制造方法和材料相比提供的几个优点在于例如优良的透射率和表面性质(由于模制玻璃的高粘度能够避免其填充模具表面内的疵点,因此可以获得近乎完美的形状)。尽管模制玻璃由于其优良的光学性质目前被优选地用来制作光学元件
110
,但是,用其它透光材料和/或制作技术形成的光学元件也可以获得一些上述优点。举例来说,可以机械加工并抛光透明塑料,形成单片的光学元件
110
,或者胶合或以其他方式固定单独的几片来形成光学元件
110
。
图
2
是示出工作期间的聚光型太阳能收集器
100
的侧视图。类似于传统的聚光型太阳能收集器,利用收集器定位***(未示出,该***例如是在
Amonix, Incorporated of
Torrance, California, USA
制造的
MegaModule
TM
***内所用的跟踪***)来定位聚光型太阳能收集器
100
,使得光束
LB
(例如太阳光线)沿着期望方向(例如垂直于开孔表面
115
)被引导到开孔表面
115
内。光伏电池
112
基本上设置在聚光区域
F
内,聚光区域
F
指的是光束
LB
被主镜
130
、次镜
140
以及任何其它***光学结构(例如,介电通量聚光器)聚集到的区域。在该公开的实施例中,聚光区域
F
与中央区域
113
相重合,该聚光区域
F
被用传统的取放以及/或光刻处理进行平面化(平坦化)处理,以便有利于安装光伏电池
120
并进行相关的布线。需要注意,中央区域
113
位于正下方,并由此由次镜
120
的“阴影”确定。还需要注意,在主镜
130
内确定一个开口
139
,以有利于光通过中央区域
113
到达光伏电池
120
。为了便于在中央区域
113
内定位聚光区域
F
,凸面
112
、主镜
130
、凹面
117
以及次镜
140
都以光轴
X
为中心并且关于光轴
X
基本对称,光轴
X
基本上垂直于开孔表面
115
延伸(即,凸面
112
和凹面
117
的弯曲部分由围绕着光轴
X
转动的圆弧确定)。另外需要注意的是,焦深(即次镜
140
与光伏电池
120
之间的距离)可以依据所选择的光学***进行调节。例如,光学***可以被选择为产生较短的焦距,从而有利于使中央区域
113
(并且由此,光伏电池
120
)凹进光学元件
110
内。或者,光学***可以被选择为产生较长的焦距,从而有利于在凸面
112
之下延伸的台面的末端处形成中央区域
113
。
光学元件
110
的尺寸和形状可以进行改变以最优化特定的功能。对于产生期望功率输出所需的更大数量的聚光器,与用较大聚光器构建的模块相比,用直径相对较小的固态聚光器构建的模块将需要更多的装配时间,但是,这样的模块将比用较大聚光器构建的模块引起较少的吸收损耗。另外,如上所建议地,主镜
130
和次镜
140
的形状可以采用各种形状,以获得理想的聚光区域。在一个特定实施例中,光学元件
110
的外径为
28mm
,凹面
117
的外径为
6.8mm
,厚度为
7.5mm
,凸面
112
形成为双曲线面,半径为
15.000mm
,圆锥常数为
-1.030
,凹陷
117
也形成为双曲线面,半径为
3.438mm
,圆锥常数为
-2.752
。在另一个实施例中,凸面
112
是抛物面,凹面
117
是双曲线面。光学领域的熟练人员将认识到,还可以利用其他的圆锥形或以其它形式弯曲的表面来获得将光传输到光伏电池
120
所需的内反射。
光伏电池
120
直接安装在光学元件
110
上,与光学元件
110
相邻安装,这取决于聚光区域
F
的位置以及中央区域
113
的位置。如图
2
所示,在一个实施例中,中央区域
113
包括基本上定位在凸面
112
顶点处的平坦、圆形区域。在其他的实施例中,中央区域
113
可以凹进光学元件
110
内(即,更接近凹面
117
),或者定位在一个突起结构上(即,更远离凹面
117
)。在一个实施例中,光伏电池
120
借助于例如硅酮的填隙透明粘合剂
128
(例如聚联苯硅氧烷(
polydiphenylsiloxane
)或聚甲基苯基硅氧烷(
polymethylphenylsiloxane
))安装在中央区域
113
上,该填隙透明粘合剂
128
用来将中央区域
113
外表面与光伏电池
120
之间折射率的中断(
disruptive break
)降至最小。光伏电池
120
然后可以借助于标准的引线接头
124
连接到外部的布线。适合的光伏(聚光型太阳能)电池例如是由
Spectrolab, Inc. of
Sylmar, California, USA
制造的。
依照本发明的另一个方面,光学元件
110
被用作底板结构,用于支撑光伏电池
120
以及导体
121
和
122
,导体
121
和
122
借助于传统的引线接头结构
124
和/或焊接互连连接到光伏电池
120
。在一个实施例中,导体
121
和
122
可以例如借助于绝缘(介电)层在主镜
130
之上印刷或者蚀刻导电材料来形成。在另一个实施例中,如下所述,利用主镜材料来形成导电通路(即,从而消除对单独的导体
121
和
122
的需求)。
图
3
和图
4
是示出依照本发明另一个实施例的聚光型太阳能收集器
200
的顶面分解透视图和底面装配透视图。类似于聚光型太阳能收集器
100
,聚光型太阳能收集器
200
包括光学元件
210
,光伏电池
220
,主镜
230
以及次镜
240
。光学元件
210
在形状上类似于光学元件
110
,包括上部区域
211
、对大的凸面
212
、基本平坦的开孔表面
215
以及相对小的凹面
217
。光伏电池
120
定位在中央区域
213
内。主镜
230
和次镜
240
基本上以上述的方式但以下述的特征分别形成在凸面
212
上和凹面
127
上。
如图
3
所示,光学元件
210
的上部区域
211
的围缘包括六个邻接的小面
219
。如下面进一步详细说明,这种六面设置有利于以高度空间有效的方式形成大阵列的聚光型太阳能收集器
200
。在其他实施例中,可以使用具有其它周边形状(例如,如上所述,圆形周边形状的聚光器
100
)的聚光器来制造空间效率较低的聚光型太阳能收集器阵列。
依照本发明的另一个方面,主镜
230
包括设置在凸面
212
第一半上的第一金属膜部分
231
和设置在凸面
212
第二半部上的第二金属膜部分
234
。第一金属膜部分
231
包括半六边形的围缘
232
和基本半圆形的内缘
233
,第二金属膜部分
234
包括半六边形的围缘
235
和基本半圆形的内缘
236
。在内缘
233
与内缘
236
之间确定一个薄的间隙
237
,以有利于金属膜部分
231
和
234
之间的电绝缘,该间隙
237
设置得尽可能窄,避免反射光的损耗。如下面另外详细说明地,采用两个或多个间隔开的金属膜部分形成主镜
230
有利于将主镜
230
用作导电通路,该导电通路将聚光型太阳能收集器阵列内相邻收集器的光伏电池电学地联接起来。类似于收集器
100
(如上所述),凸面
212
设置有平坦的中央区域
213
。在本实施例中,主镜
230
包括对应的平坦结构,该平坦结构包括整体地连接到第一金属膜部分
231
的第一平坦部分
238A
,和整体地连接到第二金属膜部分
234
的第二平坦部分
238B
。依照另一方面,这些平坦部分也被间隙
237
分开,这些平坦部分中的一个(例如,第一平坦部分
238A
)确定开口
239
,该开口
239
与光轴
X
相重合,以有利于反射光穿过并到达光伏电池
220
,光伏电池
220
基本上如上所述和如图
4
所示固定在平坦中央部分
213
上。
图
5
是示出依照本发明另一个实施例的固态透光光学面板
300
的透视图,图
6
是示出包括光学面板
300
的聚光型太阳能收集器阵列
400A
的简化侧视图。
参看图
5
,光学面板
300
是一个固态透光板,其包括排列成蜂窝图案的光学元件部分
210-1
至
210-7
(用虚线绘出)的集成阵列,其中每个光学元件部分
210-1
至
210-7
都基本与光学元件
210
(如上面参看图
3
和
4
所述的)相同。这样,光学面板
300
包括:具有多个突起(凸面)
212
的下表面
305
,这些突起
212
被槽
307
(如图
6
所示)分开;以及基本上平坦的孔径(顶)表面
315
,该开孔表面
315
包括相对很小、隔开的凹陷(凹面)
217
,每一个突起
212
与相联的凹陷
217
关于相联的光轴
X-1
至
X-7
对称,其中光轴
X-1
至
X-7
穿过这两个结构的中心。例如,光学元件部分
210-1
包括关于光轴
X-1
对称并且被光轴
X-1
贯穿的突起
212-1
和凹陷
217-1
。如图
6
所示,开孔表面
315
由相邻光学元件部分的邻接开孔表面部分
215
总体形成。例如,开孔表面
315
的部分
315-1
由光学元件部分
210-1
的开孔表面部分
215-1
和光学元件部分
210-2
的开孔表面部分
215-2
形成。光学面板
300
提供的优点在于它有利于以节省空间的方式将许多很小的收集器排列在一起,以防止玻璃的体积变得过大,而且在不需要有源冷却的条件下保持每个
PV
电池的功率量易于管理。另外,开孔表面
315
基本上是平坦的,从而相对易于清洁,由此降低维护成本。在该优选实施例中,光学元件面板
300
为
5
到
20mm
厚,每个聚光器
200
为
20
到
80mm
宽。因此,光学面板
300
相对较薄和平坦,从而比较容易进行模制。
图
6
示出包括串联电连接的聚光型太阳能收集器
200-1
、
200-2
和
200-3
的阵列部分
400A
,其中每个聚光型太阳能收集器
200-1
、
200-2
和
200-3
基本上与聚光型太阳能收集器
200
(如上面参看图
4
所述的)相同。依照本发明的另一个方面,相邻收集器的金属膜部分在相邻的槽处整体地连接,相邻收集器的金属膜部分通过相联的光伏电池电耦合,从而在相邻的收集器之间形成导电通路。例如,收集器
200-1
的金属膜部分
231-1
和
234-1
通过光伏电池
220-1
电耦合,而且收集器
200-1
的金属膜部分
234-1
在槽
307-1
处连接到收集器
200-2
的金属膜部分
234-2
。收集器
200-2
和
200-3
类似地联接在一起,从而形成包括收集器
200-1
、
200-2
和
200-3
的串联的收集器“行”。依照一个实施例,每个收集器收集器
200-1
、
200-2
和
200-3
还包括旁路二极管
225
,每个旁路二极管具有连接到其第一金属膜部分
231
的阳极和连接到其第二金属膜部分
234
的阴极。例如,收集器
200-1
包括二极管
225-1
,其具有连接到金属膜部分
231-1
的阳极和连接到金属膜部分
234-1
的阴极。旁路二极管
225
通过促使绕过由于其光伏电池故障而不正常工作的收集器而有利于串联操作(即,避免出现断路状态)。本领域的熟练人员将认识到,旁路电阻仅代表有利于这种串联操作的一种电路情况。
图
7
是示出依照本发明另一个实施例的聚光型太阳能收集器
200-8
的横截面侧视图。该聚光型太阳能收集器
200-8
基本上与收集器
200-1
至
200-7
(如上所述)相同,但具有下面任选的特征。
依照图
7
所示的第一个可选实施例,聚光型太阳能收集器
200-8
利用表面安装集成电路封装来在金属膜部分
231
和
234
上安装光伏电池
220
和旁路二极管
225
。在该实施例中,旁路二极管
225
例如用焊料凸块(
solder bump
)进行安装,以使旁路二极管
225
横跨间隙
237
,其阳极连接到金属膜部分
231
的延伸部分,其阴极连接到金属膜部分
234
的延伸部分。类似地,光电二极管电池
220
包括便于安装到金属膜部分
231
上的前侧安装封装(
front-side mounting
package
),以使光电二极管电池
220
的光接收区域定位在开口
239
之上。
依照另一个备选实施例,聚光型太阳能收集器
200-8
包括安装到光电二极管电池
220
背部表面上的散热器,并包括连接到金属膜部分
231
和
234
的臂,从而有利于操作期间有效地传热。需要注意,散热器
230
还可以提供光电二极管电池
220
到金属膜部分
231
和
234
上中至少一个的电连接的至少一部分(例如,通过将光电二极管电池
220
的阳极连接到金属膜部分
234
)。在一种备选制造方法中,光电二极管电池和旁路二极管可以安装在特定的散热器结构上,该特定的散热器结构在安装在相联的突起上时提供与主镜金属膜部分的所有电学连接,从而有利于用于在安装成阵列之前测试光电二极管电池的便捷交通工具(
convenient vehicle
)。在另一个备选实施例(未示出)中,光伏电池可以凹进光学面板内,实施成基板的散热器定位在凹进区域的边缘上,该基板横跨或者以其他方式连接到反射镜金属膜部分。
依照又一个备选实施例,一个密封剂结构
720
(例如,玻璃或塑料)形成在次镜
204
上,使次镜
240
密封在该密封剂结构
720
的波状(
contoured
)(弯曲)下表面
722
与光学面板部分
210-8
的凹面
217
之间。该密封剂结构
720
的上表面
725
是平坦的,且与部分
210-8/
光学面板
300
的上表面
215
/
315
共面。密封剂结构
720
通过提供完全平坦的表面,用来进一步简化维护/清洁处理,同时还用来防止次镜
240
由于暴露于环境下而被侵蚀。尽管并未示出,但是类似的密封剂层和/或加强结构可以设置在光学面板的下侧上,用来加强并保护主镜膜。
图
8
(
A
)、
8
(
B
)以及
8
(
C
)是示出依照本发明另一个实施例、在制作过程期间的示例性聚光型太阳能收集器
200-9
的下部中央区域的透视图。该聚光型太阳能收集器
200-9
基本与收集器
200-1
至
200-7
(如上面讨论的)相同,但具有下面附加的特征。
参看图
8
(
A
),金属膜
231
和
234
如上所述分别形成有平坦部分
238A
和
238B
。在本实施例中,金属膜
231
的平坦部分
238A
设置有一个突起部分
804
,该突起部分
804
限定开口
239
,金属膜
234
的平坦部分
238B
限定凹进区域
808
,该凹进区域
808
提供了突起部分
804
所需的面积,同时在内缘
233
与
236
之间存在着隔开间隙
237
。如图
8
(
B
)所示,介电层
810
(例如,焊料掩模)然后形成在金属膜
231
和
234
的平坦部分
238A
和
238B
之上(即,桥接间隙
237
),穿过介电层
810
限定通路
820
和
825
,以暴露平坦部分
238A
和
238B
的下表面。介电层可以用已知技术,如喷射印刷或丝网印刷来应用。参看图
8
(
C
),然后使用高速取放设备放置光伏电池
220
和旁路二极管
225
,使从相联封装(或裸露芯片)的下表面伸出的焊料凸块分别安置在介电层
810
内形成的相联通路上。然后进行回流焊接处理,将光伏电池
220
和旁路二极管
225
固定在平坦的金属膜部分
238A
和
238B
上。如通路
820
的放置所示,焊料凸块将光伏电池
220
连接到突起部分
804
的围缘(图
8
(
B
)),从而需要单独连接到金属膜
234
。在该实施例中,这种连接借助于任意的引线接合处理来实现,以在例如光伏电池
220
的阳极或阴极与金属膜
234
的平坦部分
238B
之间产生引线接合
815
。
图
9
是示出依照本发明的另一个实施例制造的聚光型太阳能收集器阵列
400B
的底部透视图。阵列
400B
包括排列成平行的行的多个收集器
200-11
至
200-14
、
200-21
至
200-25
、以及
200-31
至
200-34
,收集器
200-11
至
200-14
形成第一行,收集器
200-21
至
200-25
形成第二行,收集器
200-31
至
200-34
形成第三行。图
9
所示的每个收集器基本上与图
8
所示的收集器
200-9
相同。如上所述,每个收集器的金属膜片段(
segment
)都通过相关联的光电二极管电池和可选旁路二极管进行电学耦合。例如,以间隙
237-11
隔开的金属膜
231-11
和
234-11
以上述方式通过光电二极管电池
220-11
和旁路二极管
225-11
电学耦合。另外,每行中每个相邻收集器的金属膜连接,以形成相联的金属膜片段。例如,收集器
200-11
的金属膜
234-11
和收集器
200-12
的金属膜
231-12
沿着接缝
901
连接,以形成基本上半沙漏形(
hour-glass-shaped
)的金属膜片段
900-11
。类似地,收集器
200-12
的金属膜
234-12
和收集器
200-13
的金属膜
231-13
沿着相关联的接缝
901
连接,以形成金属膜片段
900-12
。从而,用于包含收集器
200-11
至
200-14
的行的导电通路由金属膜片段
900-11
至
900-14
形成。类似地,用于包含收集器
200-21
至
200-25
的行的导电通路由金属膜片段
900-21
至
900-25
形成,用于包含收集器
200-31
至
200-34
的行的导电通路由金属膜片段
900-31
至
900-34
形成。
相邻金属膜片段之间的电绝缘(即,间隙
237
),以及相邻金属膜片段行之间的电绝缘通过在相邻金属膜片段行之间蚀刻出或以其他方式形成狭长的间隙来提供。例如,金属膜片段
900-11
至
900-14
与金属膜片段
900-21
至
900-25
用狭长间隙
937-12
隔开。类似地,金属膜片段
900-21
至
900-25
与金属膜片段
900-31
至
900-34
用狭长间隙
937-34
隔开。依照一个实施例,金属膜片段
900-11
至
900-34
包括光学面板上的溅射的银层。然后,例如用已知的蜡染(
wax-printing
)技术形成掩模。可以利用双侧印刷以确定出光学***的两侧。随后,光学面板沉浸在一个或多个电镀槽内,以累积串式布线(
string wiring
)所需的金属厚度。在一个实施例中,电镀的铜或镍层形成在银层上,而不是镀在掩模上。铜的厚度需要为约
1
微米,以便用作充分导电的层,将电损耗限制为低于转换功率的
1
%。一旦完成电镀,剥离掩模,并将电镀金属用作蚀刻掩模蚀刻掉金属镜面涂层。这样做的目的在于从上侧的透光孔(暴露形成在其上的抗反射涂层)蚀刻掉镜面金属,并且打开下侧上的间隙
237
和
937
以形成需要的金属膜片段。然后用上述的方法进行随后处理,例如安装光伏电池。
图
10
是示出依照本发明另一个实施例的聚光型太阳能收集器单元
400C
的平面图。聚光型太阳能收集器单元
400C
包括以上述方式形成的光学面板
300C
、用于支撑和保护光学面板
300C
的金属支撑框架
410
(例如,铝或钢)、用于将收集器单元
400C
安装在收集器阵列网络(未示出)内的插接件
420
。光学面板
300C
包括数行聚光型太阳能收集器,这些收集器如上所述由金属膜片段
900-11
至
900-87
链接起来。端部片段
910-12
、
910-23
、
910-34
、
910-45
、
910-56
、
910-67
以及
910-78
以示出的方式在相邻的行之间提供连接,部分片段
910-1
和
910-8
与金属化片段
910-81
一起用来在这些收集器与插接件
420
之间提供连接。示出的片段图形是大大地简化的,仅被用来提供图解的目的,本领域的熟练人员将认识到,可以采用许多种替代的图形。将每个相邻的收集器隔开的圆包括例如如上所述的介电区域和电路组件(例如,光伏电池
200-11
被示出位于片段
900-11
与
900-12
之间)。尽管在单元
400C
中示出的所有收集器连接成一条串行的串(
string
),该串包括由端部片段相链的所有八行,但是可以理解,可以以类似的方式形成在每个单元上两个或多个串行的串。
虽然已经针对某些特定的实施例描述了本发明,但是对于本领域的熟练人员很清楚地是,本发明这些创造性的特征也可以应用于其它实施例,所有这些都应当落入本发明的范围内。例如,在以如上所述的方式将次镜形成在第一(前)片(
pane
)、将主镜形成在第二(背)片这种两片的布置中,也可以实现本发明的一些有益方面。虽然这样的布置得益于例如利用主镜膜来提供串式布线,但是这样的布置需要在装配期间定位所述片,从而增加了维护成本。在另一个备选实施例中,主镜和次镜可以预先形成,然后用合适的粘合剂安装到光学元件上,但是这种方法会显著增加制造成本。在又一个实施例中,形成次镜所利用的曲面可以是凸面而不是凹面,从而呈传统的格雷戈里(
Gregorian
)型***的状态。在另一个实施例中,形成主镜和次镜所利用的曲面可以是椭圆形、椭球形、球形或者其它的弯曲形状。
Claims (23)
1.一种聚光型太阳能收集器,包括:
固态透光光学元件,其具有包括相对较大凸面的第一侧、包括开孔表面的第二侧、以及在所述开孔表面的中央部分内确定的相对较小的曲面;其中所述开孔表面基本平坦,使得垂直射向所述开孔表面、穿过所述开孔表面、同时穿过所述开孔表面和所述凸面之间的所述光学元件的平行光束保持平行;
设置在所述凸面上的主镜;以及
设置在所述曲面上的次镜,
其中所述主镜包括设置在所述凸面的第一区域的第一金属膜部分,以及设置在所述凸面的第二区域、且与所述第一金属膜部分通过缝隙隔开的第二金属膜部分,
其中,所述聚光型太阳能收集器还包括设置在由所述第一金属膜部分和第二金属膜部分中的至少一个限定的开口上、且电连接在所述第一金属膜部分和第二金属膜部分之间的光伏电池。
2.根据权利要求1的聚光型太阳能收集器,还包括安装在为所述凸面所包围的中央区域上的光伏元件。
3.根据权利要求1的聚光型太阳能收集器,其中所述主镜和次镜包括分别在凸面和曲面上直接地形成的各反射镜膜。
4.根据权利要求3的聚光型太阳能收集器,其中所述主镜和次镜包括相同的反射镜材料。
5.根据权利要求1的聚光型太阳能收集器,其中所述光学元件还包括由所述凸面包围的平坦中央区域,
其中所述平坦中央区域定位成使得它被光轴横切;以及
其中所述第一金属膜部分和所述第二金属膜部分的每一个包括设置在所述平坦中央区域的平坦部分。
6.根据权利要求1的聚光型太阳能收集器,还包括具有连接到所述第一金属膜部分的阳极和连接到所述第二金属膜部分的阴极的旁路二极管。
7.根据权利要求1的聚光型太阳能收集器,还包括安装在所述光伏电池上的散热器。
8.根据权利要求1的聚光型太阳能收集器,还包括设置在所述光伏元件和所述光学元件的中央区域之间的介电层。
9.根据权利要求1的聚光型太阳能收集器,还包括形成在所述次镜上的密封剂结构,使得所述次镜处在所述密封剂结构的曲面和所述光学元件的曲面之间。
10.根据权利要求1的聚光型太阳能收集器阵列,其中所述主镜和次镜限定焦点区,并且其中所述焦点区位于所述固态光学元件的凸面下延伸的台面上。
11.一种聚光型太阳能收集器,包括:
固态透光光学元件,其具有包括相对较大凸面的第一侧、包括基本平坦的开孔表面的第二侧、以及在所述开孔表面的中央部分内确定的相对较小的曲面;
设置在所述凸面上的主镜;以及
设置在所述曲面上的次镜,
其中所述主镜和次镜限定重合的光轴,且被加工成形,使得基本上平行于所述光轴行进、且被引导穿过所述开孔表面的每个区域的光束被所述主镜的对应区域朝所述次镜反射,以及被述次镜的对应区域朝着为所述凸面包围的中央区域再反射,
其中所述主镜包括设置在所述凸面的第一区域的第一金属膜部分,以及设置在所述凸面的第二区域、且与所述第一金属膜部分通过缝隙隔开的第二金属膜部分,
其中,所述聚光型太阳能收集器还包括设置在由所述第一金属膜部分和第二金属膜部分中的至少一个限定的开口上、且电连接在所述第一金属膜部分和第二金属膜部分之间的光伏电池。
12.根据权利要求11的聚光型太阳能收集器,其中所述主镜限定第一圆锥面,以及所述次镜限定第二圆锥面,其中所述第一圆锥面和所述第二圆锥面对齐,使得平行于光轴射到所述第一圆锥面的任何点上的光束被反射到所述第二圆锥面的对应点,以及从所述对应点反射到所述中央区域。
13.根据权利要求11的聚光型太阳能收集器,其中所述凸面和曲面关于光轴基本对称,所述开孔表面基本上垂直于所述光轴。
14.一种聚光型太阳能收集器,包括:
固态透光光学元件,该固态透光光学元件包括光学材料,以及具有包括相对较大凸面的第一侧、包括平坦的开孔表面的第二侧、以及在所述开孔表面的中央部分内限定的相对较小曲面,
设置在所述凸面上的主镜,其中所述主镜包括设置在所述凸面的第一区域的第一金属膜部分,以及设置在所述凸面的第二区域、且与所述第一金属膜部分通过缝隙隔开的第二金属膜部分,以及
设置在由所述第一金属膜部分和第二金属膜部分中的至少一个限定的开口上、且电连接在所述第一金属膜部分和第二金属膜部分之间的光伏元件,
其中所述凸面和所述曲面二者关于光轴基本对称,所述开孔表面基本上垂直于所述光轴。
15.根据权利要求14的聚光型太阳能收集器,还包括:
设置在所述曲面上的次镜。
16.根据权利要求15的聚光型太阳能收集器,其中所述主镜和所述次镜被加工成形,使得基本上平行于光轴行进并导引通过所述开孔表面的每个区域的光束由所述主镜的对应区域向所述次镜反射,以及由所述次镜的对应区域再度反射到由所述凸面包围的中央区域上。
17.根据权利要求16的聚光型太阳能收集器,还包括安装在所述中央区域上的光伏元件。
18.根据权利要求16的聚光型太阳能收集器,其中所述主镜和次镜包括分别在所述凸面和所述曲面上直接地形成的各反射镜膜。
19.一种聚光型太阳能收集器阵列,包括:
固态透光光学面板,该固态透光光学面板包括限定多个相对较大突起的第一表面,和限定多个相对较小凹陷的开孔表面,每个凹陷与相应的突起相关联,使得每个凹陷和其相关联的对应突起形成光学面板的光学元件部分,其中所述开孔表面基本平坦,使得垂直射向且通过所述开孔表面、同时通过所述开孔表面和对应的所述多个突起中的一个之间的光学元件的平行光束保持平行;
设置在所述第一表面上的多个主镜,使得每个主镜设置在所述多个突起中相应的突起的凸面上;以及
多个次镜,每个次镜设置在所述多个凹陷中对应的凹陷内,
其中所述多个主镜包括多个形成在第一表面上的隔开的金属膜片段;以及
其中所述聚光型太阳能收集器阵列还包括多个光伏电池,每个光伏电池耦合在所述多个隔开的金属膜片段中的相关联对之间。
20.根据权利要求19的聚光型太阳能收集器阵列,其中所述多个隔开的金属膜片段通过所述多个光伏电池串联耦合。
21.根据权利要求20的聚光型太阳能收集器阵列,还包括多个旁路晶体管,每个旁路晶体管与所述多个光伏电池中相关联的光伏电池并联连接。
22.一种聚光型太阳能收集器阵列,包括:
光学面板,其包括具有第一侧和第二侧的固态透光光学材料,其中仅所述光学材料设置在所述第一侧和所述第二侧之间;
安装在所述光学面板的所述第一侧上、成排布置的多个隔开的导电金属膜片段,其中每个金属膜片段包括面向所述光学面板内、朝向所述第二侧的反射表面;以及
安装在所述光学面板的第一侧上的多个光伏电池,每个光伏电池电连接在一对相邻的金属膜片段之间,使得每排所述金属膜片段通过相关联的光伏电池串联连接;
其中所述光学面板包括多个由所述光学材料形成、设置在所述第二侧上的突起,使得每个突起形成所述光学面板的相关联的光学元件部分;以及
其中所述第一侧基本平坦,使得垂直射向且通过所述第一侧、同时通过所述第一侧的开孔表面和对应的所述多个突起中的一个之间的光学面板的平行光束保持平行。
23.根据权利要求22的聚光型太阳能收集器阵列,其中所述多个金属膜片段中的每个金属膜片段在一对相邻的突起之间延伸。
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- 2006-04-14 JP JP2006111486A patent/JP5016251B2/ja not_active Expired - Fee Related
- 2006-04-18 CN CNA2006100770223A patent/CN1854637A/zh active Pending
- 2006-04-18 CN CN201410212425.9A patent/CN104052389B/zh not_active Expired - Fee Related
- 2006-04-19 PT PT61127486T patent/PT1715260E/pt unknown
- 2006-04-19 EP EP06112748.6A patent/EP1715260B1/en not_active Expired - Fee Related
- 2006-04-19 BR BRPI0601296-5A patent/BRPI0601296A/pt not_active Application Discontinuation
- 2006-04-20 IL IL175007A patent/IL175007A/en active IP Right Grant
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Also Published As
Publication number | Publication date |
---|---|
AU2006201575A1 (en) | 2006-11-02 |
JP5016251B2 (ja) | 2012-09-05 |
EP1715260B1 (en) | 2013-07-10 |
JP2006303494A (ja) | 2006-11-02 |
EP1715260A2 (en) | 2006-10-25 |
IL175007A0 (en) | 2006-08-20 |
PT1715260E (pt) | 2013-08-23 |
EP1715260A3 (en) | 2010-11-24 |
BRPI0601296A (pt) | 2006-12-19 |
US7906722B2 (en) | 2011-03-15 |
IL175007A (en) | 2012-05-31 |
CN104052389A (zh) | 2014-09-17 |
CN1854637A (zh) | 2006-11-01 |
US20060231133A1 (en) | 2006-10-19 |
AU2006201575B2 (en) | 2011-04-14 |
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