WO2017187444A1 - Multistage area concentrator for concentrated photo voltaic - Google Patents

Multistage area concentrator for concentrated photo voltaic Download PDF

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Publication number
WO2017187444A1
WO2017187444A1 PCT/IN2017/000089 IN2017000089W WO2017187444A1 WO 2017187444 A1 WO2017187444 A1 WO 2017187444A1 IN 2017000089 W IN2017000089 W IN 2017000089W WO 2017187444 A1 WO2017187444 A1 WO 2017187444A1
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Prior art keywords
concentrator
collector
cpv
primary
dual axis
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PCT/IN2017/000089
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French (fr)
Inventor
Nagasandra Shankar Rao CHANDRASEKHAR
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AGARWAL, Reema
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Publication of WO2017187444A1 publication Critical patent/WO2017187444A1/en

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    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01LSEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L31/00Semiconductor 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
    • H01L31/04Semiconductor 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
    • H01L31/054Optical elements directly associated or integrated with the PV cell, e.g. light-reflecting means or light-concentrating means
    • H01L31/0547Optical elements directly associated or integrated with the PV cell, e.g. light-reflecting means or light-concentrating means comprising light concentrating means of the reflecting type, e.g. parabolic mirrors, concentrators using total internal reflection
    • YGENERAL 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
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E10/00Energy generation through renewable energy sources
    • Y02E10/50Photovoltaic [PV] energy
    • Y02E10/52PV systems with concentrators

Definitions

  • the present invention generally relates multistage area concentrator for concentrated photo voltaic. More particularly, the present invention encompasses a comprehensive multistage CPV solution with multistage solar insolence concentrator with a provision of peaking the efficiency in terms of concentration collection followed by increase in power generation by many folds.
  • PV photovoltaic
  • the conventional technologies used for direct conversion of sunlight into electricity include, for the most part: i) building- integrated "flat-plate” PV solar panels (rooftops/solar farms), and ii) ground-based continuous flat PV arrays, both depending on direct or normal exposure to solar radiant energy to produce their rated power outputs.
  • Most of these conventional setups pose several common yet serious limitations especially when used in medium- and large-scale applications (i.e. , at the hundreds of KWs and MWs power output levels):
  • the PV solar panels require reliable weather-proofing to protect them from the long-term degradation of the weather and also large supporting metal structures occupying significant areas of land for installing hundreds of flat PV panels needed for the respective solar power plants. That adds considerable installation, maintenance & operation costs to the already high costs of the flat PV panels and their related supporting infrastructure;
  • a Dual-stage parabolic concentrator is disclosed in a PCT application WO 2015193870 A2 by Karthigueyane LAKSHMANAN et al.
  • the disclosed improvised Solar Concentrator and Absorber / Receiver Subsystem uses a Dual-Stage Parabolic Concentrator for Concentrating Solar Power (CSP) (Thermal) system comprises of two parabolic mirrored reflectors wherein their apertures face each other with their focal point/line and axes coincides with each other, a plurality of absorber tubes/cavities placed on the non- reflecting side of the primary and/or secondary reflectors to carry heat transfer fluid, combined with relevant mechanisms to prevent/minimize thermal loss, mounted on a Sun tracking mechanism.
  • CSP Concentrating Solar Power
  • Concentrating solar radiation devices can use refractive optics (e g. , parabolic mirrors, trough, cone and trapezoidal-shaped mirrors), and/or reflective optics (lens) and/or a combination of different such optical elements in one or multi-stage arrangements, to yield high concentration ratios on the order of 50*. or more suns. Precise alignments of the concentrators with the sun through adequate tracking systems can increase the energy generation up to 30%.
  • the biggest challenges of the CPV are the pointing accuracy to the sun and good thermal management in the area of the high efficiency MJ PV cells.
  • the high concentration photovoltaic (HC PV) cells require precise alignment of the optical devices with the sun— a flat PV panel is able to perform at 90% of its maximum power output even with 20 degrees angular error of its tracking system, while an angular error greater than ⁇ 2 degrees in a CPV assembly would render the system's power generation essentially down to zero (see, U. S. Pat. No. 6,091 ,020).
  • flat panels can take advantage of the diffusively reflected sunlight from the environment, which the CPV cannot access—for example, if a flat PV panel receives 1 ,000 W/m 2 in total irradiance, a CPV can access only 850 W/m 2 , which is direct normal irradiance. Therefore, with the CPV systems, accurate sun tracking is crucial. Thermal management of the CPV systems has all the thermal challenges of the flat PV systems and, in addition, the challenge of having to conduct heat away from a considerably smaller area of the PV cells than that of the conventional flat PV panels.
  • cooling methods can be employed to effectively combat heat build-up in a CPV system including passive cooling heat sinks, active heat sinks (e.g. , water cooling) or spectral cooling, depending on the specifics of the system application and the best fit cooling option for the system integration.
  • CPV systems are generally grouped into three classes depending on the level of solar concentration:
  • Low-concentration CPV 2 - 10 suns - these are the simplest systems; they can usually use conventional silicon solar cells, and usually do not require active cell cooling. Low concentration stationary non-imaging optics is most suitable for this application.
  • Medium-concentration CPV 10 - 100 suns - these systems may use either conventional silicon solar cells or high-efficiency lll-V multi-junction cells and usually require active cell cooling.
  • One-axis tracking linear concentrators are most suitable for this application.
  • High-concentration CPV 100 - 1000 suns - these systems require extremely efficient (>35%) multijunction cells and sophisticated cell thermal management systems Two-axis tracking point focus or multistage concentrators are required for this application.
  • the present invention primarily relates to a multistage solar concentrated photo voltaic arrangement configured for harvesting solar energy.
  • the available solar insolence is concentrated multiple times before using i.e. exposing it to solar cells.
  • the proposed systematic approach is closed loop, multiple stage wise reflective and supervisory controlled and is designed to accommodate the whole arrangement on a single base and using a very small area. While the arrangement can be easily installed as a stand-alone portable/remote solar power system or incorporated in a building structure as a building-integrated power application.
  • a multistage dual axis four quadrant area concentrator for CPV comprising ofa primary parabolic reflective concentrator with aperture configured to focus the orthogonally incoming collimated solar insolence toward a focal point f(p);at least one collector concentrator, which is essentially a feed reflective conical aperture concentrator with a focal point f(c), a receiver concentrator (solar panel), which is an array of photovoltaic cells, placed over a conical surface and positioned with a focal point f(r), which is measured from the focal point of the collector concentrator (f(p)) and is configured to receive the multistage concentrated solar insolence from the collector concentrator; wherein the primary concentration levels are achieved by the ratio of f ⁇ p)/f(c) which is also the ratio of the linear dimensions of the primary concentrator and collector concentrator;wherein the position of the collector concentrator is f(p) + f(c); andwherein the area concentration ratio is adjustable.
  • a method for assembly of multistage dual axis four quadrant area concentrator for CPV comprising of laying and configuring a primary parabolic reflective concentrator with aperture aligned to focus the orthogonally incoming collimated solar insolence toward a focal point f(p);positioning at least one collector concentrator, which is essentially a feed reflective conical aperture concentrator with a focal point f(c); positioning a receiver concentrator, which is an array of photovoltaic cells, placed over a conical surface and positioned with a focal point f(r), which is measured from the focal point of the collector concentrator (f(p)) and is configured to receive the multistage concentrated solar insolence from the collector concentrator; wherein the primary concentration levels are achieved by the ratio of f(p)/f(c) which is also the ratio of the linear dimensions of the primary concentrator a nd collector concentrator;wherein the position of the collector concentrator is f(p) + f(c) ; and wherein the area concentration ratio is
  • It is another object of this invention to provide a multistage concentrator for solar insolence comprising collector concentrator which is subdivided into plurality of collector concentra tors facing each other and their focal axes coincide each other and further configured to be installed over a movable stand for tracking the sun in real time.
  • the reflecting surfaces of the primary and collector concentrators includes a t least one from glass, metal , polymers or synthetic materials and / or combination of any of these materials.
  • the reflecting surfaces of the primary concentrator and collector concentrators are assembled piece wise parabolic and/or conical reflectors.
  • the reflecting surfaces of the primary concentrator and collector concentrators a re secured with velcro tapes for easy repair / replacements
  • the present invention teaches a novel combination and a rrangement of parts, either commercially available or specifically designed and described below. It should be understood that changes and variations may be made in the detailed design of the parts, including the solar concentration means, the HC sunlight transmission and light distribution devices and the compact 3D CPV assembly without departing from the spirit and scope of the invention as claimed.
  • Fig 1 illustrates the basic block diagram of multistage CPV in accordance with the present invention
  • Fig 2 illustrates a line drawing of the optics of multistage CPV including three stage concentration, collection and reception in accordance with the present invention
  • Fig 3 illustrates a pictorial representation of the multistage CPV in accordance with the present invention
  • multistage reflective concentrated photo voltaic (CPV) power generation system as shown in Fig 3 and the method thereof such as herein described is selected systems selected for the purpose of illustrating the invention include a primary parabolic sunlight concentrator, a plurality collector concentrators and a receiver.
  • CPV photo voltaic
  • Fig, 1 shows a block schematic diagram of the proposed system with multistage CPV- system for concentrating and transforming solar energy into electrical energy.
  • the proposed system includes a primary parabolic concentrator configured for reflecting all impinging solar insolence to its focal point which is collected and further concentrated by a secondary collector concentrator and thereafter exposed to a receiver solar panel configured for efficient conversion of concentrated solar insolence to equivalent electrical power.
  • there may be a plurality of collector concentrators wherein the said collector concentrators face each other and their focal axes coincide each other. Further the focal axis of the primary concentrator is also coinciding with the focal axes of the collector concentrators.
  • the plurality of collector concentrators are so arranged so that the solar insolence reflected by the primary concentrator gets reflected and concentrated from first collector and thereafter second collector and so on till it hits the solar panel.
  • FIG. 2 A line schematic diagram showing the multiple reflections through primary concentrator and collector concentrator is shown in Fig 2.
  • the arrangement may further include a sun sensing and sun tracking mechanism configured for sensing and tracking the real time location and intensity of the available sun light as exemplary embodiments.
  • the sun sensing and tracking mechanism as discussed herein is based on 2 ⁇ 4 quadrant topology.
  • the sun position sensor is mounted on disclosed multistage concentrated photo voltaic system for real time sensing and tracking of sun round the clock over the year continuously.
  • the optics for the disclosed multistage CPV comprises of three stage concentration collection and reception as shown in Fig 2 (a) and (b).
  • the optics essentially comprises of an octagonal mirrored primary concentrator using array of special mirrors which are explained in the section below to concentrate the sunlight falling on penumbra regions and which is normal to the axis of the parabola at a focal point (F1 ) with a length of (f1 ).
  • a secondary collector mirror which is also an array of mirrors and positioned at the intersection of primary focal point and a secondary focal point f2 with a separation of 2xf2.
  • the collector parabolic dish collects all the reflected light from the primary concentrator and refocus it to a point F2 which is at a distance of 2 * f2.
  • the available flatbed solar panel with an area of (A) is positioned at a distance of F2 from the collector parabola in both the axes (xx-yy).
  • a concentrator is designed to operate under illumination for greater than 40 to 100 suns.
  • the short-circuit current from a solar cell depends linearly on light intensity, such that a device operating under 40 suns would have 40 times the short-circuit current as the same device under one sun operation.
  • this effect does not provide an efficiency increase, since the incident power also increases linearly with concentration. Instead, the efficiency benefits arise from the logarithmic dependence of the open-circuit voltage on short circuit. Therefore, under concentration, Voc increases logarithmically with light intensity, as shown in the equation below; where X is the concentration of sunlight
  • the primary concentration levels are achieved by the ratio of f(p)/f(c) which is also the ratio of the linear dimensions of the primary concentrator and collector concentrator wherein f(p) is the focal length of primary and f(c) is the focal length of the collector
  • Normal solar PV with 1 2 to 18% efficiency will generate a power of the order of 120 watts to 180 watts / meter 2 of solar cells which are essentially connected either in series or parallel ( Electrically) to obtain the required Voltage and current.
  • the current is linear with insolence, Hence by collecting the sun light over a large area and direct the concentrated light to a Receiver like solar PV module generates at higher current Thus CPV achieves higher power output from the conventional solar panel.
  • the area concentration is the product of longitudinal concentration and Lateral concentration C_ longitude x C _ Lateral.
  • the power output from the panel is 6000 watts and thermal radiation on the CPV module is of the order 32000 to 34000 watts.
  • This example exhibits the merit of performance of CPV which generates the power from 240 watts to 10000 watts with a receiver area of 1 6 meter 2 .
  • the area of collector area need to be 40 times the size of receiver (Solar PV module) i.em 2 (which will be achieved by area concentration of ( 5 times longitudinal direction and ( 5x 1.6 times in the lateral direction)
  • a typical size of CPPV is explained below:-
  • the overall concentration will be 40 x or higher
  • the efficiency benefits of concentration may be reduced by increased losses in series resistance as the short-circuit current increases and also by the increased temperature operation of the solar cell. As losses due to short-circuit current depend on the square of the current, power loss due to series resistance increases as the square of the concentration.
  • the primary concentrator and collector concentrators are assembled in piece wise parabolic and conical reflectors
  • Pieces of reflector panels are fixed over a parabolic base to form a primary concentrator. These pieces are fixed over the base by using readily available Velcro tapes so that they can be easily attached and replaced.
  • the sides defining the front surface of the reflector panels form the shape of a square
  • reflector panels with any shape or combination of shapes which facilitate efficient packing within a two-dimensional plane as is well-known in the art Examples include triangular, rectangular, hexagonal, or octagonal shapes.
  • the reflector panels preferably have a front surface which is optically flat and provides for specular reflection of incident radiation.
  • each reflector panel comprises male and female connectors formed at each side of the reflector panel at positions along the panel centerlmes.
  • the connector type preferably alternates between male and female around the perimeter of each individual reflector panel.
  • the male and female connectors are capable of interlocking via a snap-together feature A taper is incorporated into the interlock such that when a plurality of reflector panels are arranged into a two-dimensional array, the entire grid of reflector panels can be contoured to the desired bend angle in both horizontal and vertical directions.
  • the bend angle is such that the surface contour formed by the arrayed reflector panels corresponds with surface of a parabola or cone.
  • the reflector panels are formed from a plastic or composite material which yields a finished product of excellent hardness, rigidity, and durability and which is compatible with the process used to impart reflectivity to the front surface.
  • the reflector panels may be formed from a lightweight metal such as aluminum, titanium, or related metal alloys.
  • the reflector panel is formed from a granular plastic material comprising a plastic material and an inorganic additive.
  • the plastic may be selected from polycarbonate, olefin resins, ABS resin, recycled synthetic resin material, and styrol resin.
  • a specularly reflective surface may be imparted to the reflector by the formation of a highly reflective coating.
  • the reflective coating may include a hot-stamped metal foil or reflective glass-free polymer-based film having at least one reflective layer coated thereon.
  • the coating may be of nickel/copper/nickel/chromium multilayer structure.
  • the multistage concentrator according to aspects of the present invention comprises a multistage solar collection and concentration assembly. As per another aspect of the present invention there is provide a sun sensing and 2 ⁇ & 4 quadrant solar tracking system which operationalizes the dislosed multistage solar concentrator in real time for continuous uninterrupted power generation.
  • the multistage concentrator includes three stages i.e. concentration, collection of solar energy and further receiving by a solar panel for generation of solar power.
  • the primary concentrator collects the sunlight orthogonal to the tracked moving plane in 2 ⁇ &4 quadrant positioning system with feedback control.
  • dual beam frame structures for erection of the multistage concentrator as disclosed herein.
  • a thermal management system configured for nullifying the damages caused to the solar panel as the high intensity concentrated light essentially associated with the heat elements.
  • the said thermal management employs a two stage thermal management.
  • the first stage includes positioning of a thermal ba rrier between the receiver and the secondary collector.
  • switched mode solar power transfer and storage The CPV power transfer in switch mode is new concept for the regulation of solar C PV power, being harnessed to the regulator or inverter. This switching scheme improves the efficiency and minimise heat losses.

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Abstract

A multistage dual axis four quadrant area concentrator for CPV comprising of: a primary parabolic reflective concentrator with aperture configured to focus the orthogonally incoming collimated solar insolence toward a focal point f{p); at least one collector concentrator, which is essentially a feed reflective conical aperture concentrator with a focal point f(c); a' receiver concentrator, which is an array,of photovoltaic cells, placed over a conical surface and positioned with a focal point f(r), which is measured from the focal point of the collector concentrator (f(p)) and is configured to receive the multistage concentrated solar Insolence from,the collector concentrator; wherein die primary concentration levels are achieved by the ratio of f(p)/ f(c) which is also the ratio of the linear dimensions of the primary concentrator and collector concentrator; wherein the position of the collector concentrator is f(p) + f(c); and wherein the area concentration ratio is adjustable.

Description

M ULTISTAGE AREA CONCENTRATOR FOR CONCENTRATED PHOTO VOLTAIC FIELD OF INVENTION
The present invention generally relates multistage area concentrator for concentrated photo voltaic. More particularly, the present invention encompasses a comprehensive multistage CPV solution with multistage solar insolence concentrator with a provision of peaking the efficiency in terms of concentration collection followed by increase in power generation by many folds.
BACKGROUND OF THE INVENTION
Solar energy is in use world-wide. Both heat energy harvesting and direct conversion of solar to electrical power are known in the art. Nowadays, the significant surge in demand for alternative sources of energies (i.e. , wind, solar, hydro, etc ) has created opportunities for fast development of the global alternative energy infrastructure, measurable at the giga-watts levels. The construction of new solar power plants has been intensified, leading to a subsequent boost in manufacturing and generating capacities worldwide and, thus, to significant reductions in costs with the shift towards an economy of scale and minimise the land usage. Measurable drops in the PV solar panel manufacturing and installation costs resulted in comparable reductions of the overall power plant costs. However, increase in performance of the PV solar panel modules and improvements of the solar power system effectiveness through technical innovations have a more direct and stronger impact on reducing costs by allowing for a lower number of PV solar panels for a desired power output, thus a smaller footprint of the respective PV solar installation. To this end, new technological advances in the rapidly growing field of concentrated PV cells underline a genuine option for significant reductions in PV cell surface area per kW of electrical output and, therefore, a real possibility to produce electricity at competitively lower costs.
The solar light concentration for efficient solar energy harvesting is also a well-known phenomenon. Among solar electricity generation technologies, photovoltaic (PV) technologies have seen the largest growth over the last few years and PV is increasingly seen as a viable alternative for electricity generation. However, the efficiency of this technology has well known limitations: for direct solar irradiation on Si/CIGS PV panels, the efficiency of solar to electric energy conversion peaks at around 15%. Recently, commercially available multi-junction with efficiencies exceeding 40% has been developed However, the price increase associated with manufacturing these cells is much higher than the efficiency increase, making these high-efficiency cells unsuitable for normal PV panels. Concentrated photovoltaic (CPV) systems provide the solution by using an optical concentrator to concentrate the sunlight using before it reaches the cell. The result is more sun Light energy hitting the PV surface thus requiring a much smaller cell for the same electrical output. The benefit of so doing is twofold: 1 ) the economy of the system is improved by replacing expensive PV cells with less expensive optical elements; 2) the efficiency of the PV cell is augmented by higher incident solar fluxes resulting from the concentration. Using the same amount of land, CPV systems can produce more electricity, more efficiently and using much less PV material than conventional PV systems. Recent studies have shown that the majority of cost for a CPV system is represented by the concentrator, its structure, and the tracking system mechanism. Therefore the greatest cost reductions can be achieved by targeting these technologies.
Notwithstanding the progress thus far achieved, the conventional technologies used for direct conversion of sunlight into electricity include, for the most part: i) building- integrated "flat-plate" PV solar panels (rooftops/solar farms), and ii) ground-based continuous flat PV arrays, both depending on direct or normal exposure to solar radiant energy to produce their rated power outputs. Most of these conventional setups pose several common yet serious limitations especially when used in medium- and large-scale applications (i.e. , at the hundreds of KWs and MWs power output levels):
The conventional flat PV solar panels operate at conversion efficiencies ranging from 12% to 18% and, therefore, a typical solar utility plant requires a considerable number of panels as well as a large surface area to install them— for example, a 1000 kW solar power plant would require the area of a football field (i.e. ,>=10000m2) and about 4000 of the better performing 240 watts PV) flat panels currently available on the market (i.e. , 16%-18% efficiency The PV solar panels require reliable weather-proofing to protect them from the long-term degradation of the weather and also large supporting metal structures occupying significant areas of land for installing hundreds of flat PV panels needed for the respective solar power plants. That adds considerable installation, maintenance & operation costs to the already high costs of the flat PV panels and their related supporting infrastructure;
Early attempts to reduce the footprint of the PV solar installations were directed at highly compacted solar panel arrangements having multiple closely spaced solar cells mounted to function through direct interaction with incident sunlight. The prior art patents US4,023,368, evidenced the concept of a three-dimensional (3D) solar panel geometry allowing for a 33% assembly foot-print reduction by using side reflectors to direct incident sunlight onto the underside, unexposed solar cells. Further prior art US4, 153,475, discloses a more compact power-generating system having a 3D-stacked solar panel arrangement, so that direct sunlight received from the side edges of the solar panels is redirected to the facing surfaces of each of the solar panels
Further in the prior art, a Dual-stage parabolic concentrator is disclosed in a PCT application WO 2015193870 A2 by Karthigueyane LAKSHMANAN et al. The disclosed improvised Solar Concentrator and Absorber / Receiver Subsystem uses a Dual-Stage Parabolic Concentrator for Concentrating Solar Power (CSP) (Thermal) system comprises of two parabolic mirrored reflectors wherein their apertures face each other with their focal point/line and axes coincides with each other, a plurality of absorber tubes/cavities placed on the non- reflecting side of the primary and/or secondary reflectors to carry heat transfer fluid, combined with relevant mechanisms to prevent/minimize thermal loss, mounted on a Sun tracking mechanism. For Concentrating Photovoltaic (CPV) and Concentrating Hybrid Thermo-Photovoltaic (CHTPV) Systems, all or a portion of the reflectors' reflecting and/or exterior surfaces would be covered or substituted with suitable photovoltaic panels Also, it is known to the art that the cost of producing electricity with PV cells can be considerably reduced when a large area of sunlight is concentrated upon a small area of a PV cell, which is currently the most expensive component of the system on a per unit area basis. At the same time, photovoltaic materials are more efficient at higher solar intensity levels than that of ordinary sunlight. However, one important drawback associated with current use of concentrated solar energy with PV cells is the heat build-up due to their inherent low efficiencies— i.e. , only a portion of the solar energy is converted into useful (electrical) energy, the rest being absorbed as heat throughout the PV cell. It is critical that the PV cells operate within strict temperature limits in order to maintain their performance at maximum efficiency levels— therefore, adequate cooling is essential (see, US7.081 ,584). Concentrating solar radiation devices can use refractive optics (e g. , parabolic mirrors, trough, cone and trapezoidal-shaped mirrors), and/or reflective optics (lens) and/or a combination of different such optical elements in one or multi-stage arrangements, to yield high concentration ratios on the order of 50*. or more suns. Precise alignments of the concentrators with the sun through adequate tracking systems can increase the energy generation up to 30%.
Recent innovations in the field of concentrated photovoltaic (CPV) leading to high performance solar concentrators and new generations of high efficiency PV cells have increased the potential to lower costs of the production of electricity. By using cheap, well-designed optical devices that make the high performance solar concentrators capable to intensify the incident solar radiation from the strength of one sun to the order of 50-1 ,000 or more suns, the required active area of expensive semiconductor material in the PV cells is greatly reduced. However, the CPV are faced with the strong challenges of having to maximize their efficiency and lifetime while operating at elevated temperatures and high concentration solar radiation. Some of the early CPV cells, first used in space applications, are described in a number of U.S. patents including US5, 096,505; US5,217,539; US6, 091 ,020 and US6,252, 155.
The biggest challenges of the CPV are the pointing accuracy to the sun and good thermal management in the area of the high efficiency MJ PV cells. The high concentration photovoltaic (HC PV) cells require precise alignment of the optical devices with the sun— a flat PV panel is able to perform at 90% of its maximum power output even with 20 degrees angular error of its tracking system, while an angular error greater than ±2 degrees in a CPV assembly would render the system's power generation essentially down to zero (see, U. S. Pat. No. 6,091 ,020). In addition, flat panels can take advantage of the diffusively reflected sunlight from the environment, which the CPV cannot access— for example, if a flat PV panel receives 1 ,000 W/m2 in total irradiance, a CPV can access only 850 W/m2, which is direct normal irradiance. Therefore, with the CPV systems, accurate sun tracking is crucial. Thermal management of the CPV systems has all the thermal challenges of the flat PV systems and, in addition, the challenge of having to conduct heat away from a considerably smaller area of the PV cells than that of the conventional flat PV panels. It is beneficial to keep the PV cells from overheating to avoid a decrease in cell's efficiency and to also prevent thermal stresses that cause interconnect-failures Several cooling methods can be employed to effectively combat heat build-up in a CPV system including passive cooling heat sinks, active heat sinks (e.g. , water cooling) or spectral cooling, depending on the specifics of the system application and the best fit cooling option for the system integration.
CPV systems are generally grouped into three classes depending on the level of solar concentration:
1 Low-concentration CPV: 2 - 10 suns - these are the simplest systems; they can usually use conventional silicon solar cells, and usually do not require active cell cooling. Low concentration stationary non-imaging optics is most suitable for this application.
2. Medium-concentration CPV: 10 - 100 suns - these systems may use either conventional silicon solar cells or high-efficiency lll-V multi-junction cells and usually require active cell cooling. One-axis tracking linear concentrators are most suitable for this application.
3. High-concentration CPV: 100 - 1000 suns - these systems require extremely efficient (>35%) multijunction cells and sophisticated cell thermal management systems Two-axis tracking point focus or multistage concentrators are required for this application.
SUMMARY OF THE INVENTION
The present invention primarily relates to a multistage solar concentrated photo voltaic arrangement configured for harvesting solar energy. The available solar insolence is concentrated multiple times before using i.e. exposing it to solar cells. The proposed systematic approach is closed loop, multiple stage wise reflective and supervisory controlled and is designed to accommodate the whole arrangement on a single base and using a very small area. While the arrangement can be easily installed as a stand-alone portable/remote solar power system or incorporated in a building structure as a building-integrated power application. In addition the said arrangement is made considering the full use of solar insolence during dawn to dusk and over the complete year alongwith sun sensing and tracking system, which can yield an efficient, low cost system applicable for miscellaneous applications and can be scaled efficiently to a desired size as shown in fig 3.
Therefore such as herein described there is provided a multistage dual axis four quadrant area concentrator for CPV comprising ofa primary parabolic reflective concentrator with aperture configured to focus the orthogonally incoming collimated solar insolence toward a focal point f(p);at least one collector concentrator, which is essentially a feed reflective conical aperture concentrator with a focal point f(c), a receiver concentrator (solar panel), which is an array of photovoltaic cells, placed over a conical surface and positioned with a focal point f(r), which is measured from the focal point of the collector concentrator (f(p)) and is configured to receive the multistage concentrated solar insolence from the collector concentrator; wherein the primary concentration levels are achieved by the ratio of f{p)/f(c) which is also the ratio of the linear dimensions of the primary concentrator and collector concentrator;wherein the position of the collector concentrator is f(p) + f(c); andwherein the area concentration ratio is adjustable.
Further herein described a method for assembly of multistage dual axis four quadrant area concentrator for CPV comprising of laying and configuring a primary parabolic reflective concentrator with aperture aligned to focus the orthogonally incoming collimated solar insolence toward a focal point f(p);positioning at least one collector concentrator, which is essentially a feed reflective conical aperture concentrator with a focal point f(c); positioning a receiver concentrator, which is an array of photovoltaic cells, placed over a conical surface and positioned with a focal point f(r), which is measured from the focal point of the collector concentrator (f(p)) and is configured to receive the multistage concentrated solar insolence from the collector concentrator; wherein the primary concentration levels are achieved by the ratio of f(p)/f(c) which is also the ratio of the linear dimensions of the primary concentrator a nd collector concentrator;wherein the position of the collector concentrator is f(p) + f(c) ; and wherein the area concentration ratio is adjustable.
It is one object of this invention to provide amultistage dual axis four quadrant area concentrator comprising primary and collector concentrator whose apertures face each other with their focal line and axes coincides with each other.
It is another object of this invention to provide a multistage concentrator for solar insolence wherein the area concentration ratio can be adjusted by adjusting the ratio [f(p)/f(c)] and [f(c)/f(r)].
It is another object of this invention to provide a multistage concentrator for solar insolence comprising collector concentrator which is subdivided into plurality of collector concentra tors facing each other and their focal axes coincide each other and further configured to be installed over a movable stand for tracking the sun in real time.
In an exemplary embodiment, the reflecting surfaces of the primary and collector concentrators includes a t least one from glass, metal , polymers or synthetic materials and / or combination of any of these materials.
In another exemplary embodiment, the reflecting surfaces of the primary concentrator and collector concentrators are assembled piece wise parabolic and/or conical reflectors.
In yet another exemplary embodiment, the reflecting surfaces of the primary concentrator and collector concentrators a re secured with velcro tapes for easy repair / replacements Thus the present invention teaches a novel combination and a rrangement of parts, either commercially available or specifically designed and described below. It should be understood that changes and variations may be made in the detailed design of the parts, including the solar concentration means, the HC sunlight transmission and light distribution devices and the compact 3D CPV assembly without departing from the spirit and scope of the invention as claimed.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
Fig 1 illustrates the basic block diagram of multistage CPV in accordance with the present invention;
Fig 2 illustrates a line drawing of the optics of multistage CPV including three stage concentration, collection and reception in accordance with the present invention; Fig 3 illustrates a pictorial representation of the multistage CPV in accordance with the present invention;
DETAILED DESCRIPTION
The embodiments of multistage reflective concentrated photo voltaic (CPV) power generation system as shown in Fig 3 and the method thereof such as herein described is selected systems selected for the purpose of illustrating the invention include a primary parabolic sunlight concentrator, a plurality collector concentrators and a receiver.
Fig, 1 shows a block schematic diagram of the proposed system with multistage CPV- system for concentrating and transforming solar energy into electrical energy. The proposed system includes a primary parabolic concentrator configured for reflecting all impinging solar insolence to its focal point which is collected and further concentrated by a secondary collector concentrator and thereafter exposed to a receiver solar panel configured for efficient conversion of concentrated solar insolence to equivalent electrical power. In an exemplary embodiment, there may be a plurality of collector concentrators wherein the said collector concentrators face each other and their focal axes coincide each other. Further the focal axis of the primary concentrator is also coinciding with the focal axes of the collector concentrators. The plurality of collector concentrators are so arranged so that the solar insolence reflected by the primary concentrator gets reflected and concentrated from first collector and thereafter second collector and so on till it hits the solar panel.
A line schematic diagram showing the multiple reflections through primary concentrator and collector concentrator is shown in Fig 2. During the movement of the Primary Concentrator, the respective / relative movement of the collector concentrator and the receiver is similar and is a constant. The arrangementmay further include a sun sensing and sun tracking mechanism configured for sensing and tracking the real time location and intensity of the available sun light as exemplary embodiments. The sun sensing and tracking mechanism as discussed herein is based on 2ττ 4 quadrant topology. The sun position sensor is mounted on disclosed multistage concentrated photo voltaic system for real time sensing and tracking of sun round the clock over the year continuously. OPTICS:-
The optics for the disclosed multistage CPV comprises of three stage concentration collection and reception as shown in Fig 2 (a) and (b). The optics essentially comprises of an octagonal mirrored primary concentrator using array of special mirrors which are explained in the section below to concentrate the sunlight falling on penumbra regions and which is normal to the axis of the parabola at a focal point (F1 ) with a length of (f1 ). A secondary collector mirror which is also an array of mirrors and positioned at the intersection of primary focal point and a secondary focal point f2 with a separation of 2xf2. The collector parabolic dish collects all the reflected light from the primary concentrator and refocus it to a point F2 which is at a distance of 2*f2. The available flatbed solar panel with an area of (A) is positioned at a distance of F2 from the collector parabola in both the axes (xx-yy).
A concentrator is designed to operate under illumination for greater than 40 to 100 suns. The short-circuit current from a solar cell depends linearly on light intensity, such that a device operating under 40 suns would have 40 times the short-circuit current as the same device under one sun operation. However, this effect does not provide an efficiency increase, since the incident power also increases linearly with concentration. Instead, the efficiency benefits arise from the logarithmic dependence of the open-circuit voltage on short circuit. Therefore, under concentration, Voc increases logarithmically with light intensity, as shown in the equation below;
Figure imgf000011_0001
where X is the concentration of sunlight
From the equation above, a doubling of the light intensity (X=2) causes a 18 mV rise in Voc
As an example the primary concentration levels are achieved by the ratio of f(p)/f(c) which is also the ratio of the linear dimensions of the primary concentrator and collector concentrator wherein f(p) is the focal length of primary and f(c) is the focal length of the collector
Normal solar PV with 1 2 to 18% efficiency will generate a power of the order of 120 watts to 180 watts / meter2 of solar cells which are essentially connected either in series or parallel ( Electrically) to obtain the required Voltage and current. The current is linear with insolence, Hence by collecting the sun light over a large area and direct the concentrated light to a Receiver like solar PV module generates at higher current Thus CPV achieves higher power output from the conventional solar panel.
Normally for 1 W power generation
Conventional PV needs 4000 no of solar PV modules of 250 watt/module (size 1 ,6m x 1 meter)
The proposed CPV with approximately with concentration ratio of 40, only 100 No of 250 Watt modules ( size 1 .6m x 1 meter). The area concentration is the product of longitudinal concentration and Lateral concentration C_ longitude x C _ Lateral. But to achieve a concentration ratio of 40 It is proposed to multi stage concentrator with primary Linear concentration of 5 (single axis along 1 .6 m) and a secondary concentrator of 1 along 1 .6 m along 1 m direction of the solar panel and employs conical/parabolic through feed concentration For example
In the case of concentrated PV solution with concentration ratio of 40 the power output from the panel is 6000 watts and thermal radiation on the CPV module is of the order 32000 to 34000 watts. This example exhibits the merit of performance of CPV which generates the power from 240 watts to 10000 watts with a receiver area of 1 6 meter2. The area of collector area need to be 40 times the size of receiver (Solar PV module) i.em2 ( which will be achieved by area concentration of ( 5 times longitudinal direction and ( 5x 1.6 times in the lateral direction) A typical size of CPPV is explained below:-
1 st stage concentration 5 x 1.6= 8 meter in longitudinal direction.
2nd stage concentration of 1x in longitudinal direction and 1 6 x in lateral direction.
Then the overall concentration will be 40 x or higher The efficiency benefits of concentration may be reduced by increased losses in series resistance as the short-circuit current increases and also by the increased temperature operation of the solar cell. As losses due to short-circuit current depend on the square of the current, power loss due to series resistance increases as the square of the concentration.
In another specific embodiment of the invention, the primary concentrator and collector concentrators are assembled in piece wise parabolic and conical reflectors Pieces of reflector panels are fixed over a parabolic base to form a primary concentrator. These pieces are fixed over the base by using readily available Velcro tapes so that they can be easily attached and replaced. The sides defining the front surface of the reflector panels form the shape of a square However, it is within the scope of the present invention to have reflector panels with any shape or combination of shapes which facilitate efficient packing within a two-dimensional plane as is well-known in the art Examples include triangular, rectangular, hexagonal, or octagonal shapes. The reflector panels preferably have a front surface which is optically flat and provides for specular reflection of incident radiation. In one embodiment, each reflector panel comprises male and female connectors formed at each side of the reflector panel at positions along the panel centerlmes. The connector type preferably alternates between male and female around the perimeter of each individual reflector panel. The male and female connectors are capable of interlocking via a snap-together feature A taper is incorporated into the interlock such that when a plurality of reflector panels are arranged into a two-dimensional array, the entire grid of reflector panels can be contoured to the desired bend angle in both horizontal and vertical directions. The bend angle is such that the surface contour formed by the arrayed reflector panels corresponds with surface of a parabola or cone.
In one embodiment the reflector panels are formed from a plastic or composite material which yields a finished product of excellent hardness, rigidity, and durability and which is compatible with the process used to impart reflectivity to the front surface. In yet another embodiment the reflector panels may be formed from a lightweight metal such as aluminum, titanium, or related metal alloys. In an alternative embodiment the reflector panel is formed from a granular plastic material comprising a plastic material and an inorganic additive. The plastic may be selected from polycarbonate, olefin resins, ABS resin, recycled synthetic resin material, and styrol resin.
In yet another embodiment a specularly reflective surface may be imparted to the reflector by the formation of a highly reflective coating. The reflective coating may include a hot-stamped metal foil or reflective glass-free polymer-based film having at least one reflective layer coated thereon. The coating may be of nickel/copper/nickel/chromium multilayer structure. The multistage concentrator according to aspects of the present invention comprises a multistage solar collection and concentration assembly. As per another aspect of the present invention there is provide a sun sensing and 2ττ& 4 quadrant solar tracking system which operationalizes the dislosed multistage solar concentrator in real time for continuous uninterrupted power generation.
As per one of an exemplary embodiment the multistage concentrator, includes three stages i.e. concentration, collection of solar energy and further receiving by a solar panel for generation of solar power. The primary concentrator collects the sunlight orthogonal to the tracked moving plane in 2π&4 quadrant positioning system with feedback control. As per another embodiment of the present invention, there is provided dual beam frame structures for erection of the multistage concentrator as disclosed herein. As per another embodiment of the present invention, there is provided a thermal management system configured for nullifying the damages caused to the solar panel as the high intensity concentrated light essentially associated with the heat elements. The said thermal management employs a two stage thermal management. The first stage includes positioning of a thermal ba rrier between the receiver and the secondary collector. As per another embodiment of the present invention there is provided switched mode solar power transfer and storage The CPV power transfer in switch mode is new concept for the regulation of solar C PV power, being harnessed to the regulator or inverter. This switching scheme improves the efficiency and minimise heat losses.
Although the foregoing description of the present invention has been shown and described with reference to particular embodiments and applications thereof, it has been presented for purposes of illustration and description and is not intended to be exhaustive or to limit the invention to the particular embodiments and applications disclosed. It will be apparent to those having ordinary skill in the art that a number of changes, modifications, variations, or a lterations to the invention as described herein may be made, none of which depart from the spirit or scope of the present invention. The particular embodiments and applications were chosen a nd described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such changes, modifications, va riations, and alterations should therefore be seen as being within the scope of the present invention as determined by the appended claims when interpreted in accordance with the breadth to which they a re fairly, legally, and equitably entitled .

Claims

WHAT CLAIMED IS:
1 . A multistage dual axis four quadrant area concentrator for CPV comprising of:
a primary parabolic reflective concentrator with aperture configured to focus the orthogonally incoming collimated solar insolence toward a focal point f(p); at least one collector concentrator, which is essentially a feed reflective conical aperture concentrator with a focal point f(c); a receiver concentrator, which is an array of photovoltaic cells, placed over a conical surface and positioned with a focal point f(r), which is measured from the focal point of the collector concentrator (f(p)) and is configured to receive the multistage concentrated solar insolence from the collector concentrator; wherein the primary concentration levels are achieved by the ratio of f(p)/f(c; which is also the ratio of the linear dimensions of the primary concentrator and collector concentrator; wherein the position of the collector concentrator is f(p) + f(c); and wherein the area concentration ratio is adjustable.
2 A multistage dual axis four quadrant area concentrator for CPV as claimed ir claim 1 , wherein the primary parabolic reflective concentrator has a dimension largei than the largest dimension of the collector concentrator.
3 A multistage dual axis four quadrant area concentrator for CPV as claimed ir claim 1 , wherein the aperture of the primary and collector concentrator face each othei with their focal line and axes coincides with each other,
4 A multistage dual axis four quadrant area concentrator for CPV as claimed ir claim 1 , wherein the area concentration ratio can be adjusted by adjusting the ratic
[f(p)/f(c)] and [f(c)/f(r)j\
5. A multistage dual axis four quadrant area concentrator for CPV as claimed in claim 1 , wherein the collector concentrator is subdivided into plurality of collector concentrators facing each other and their focal axes coincide each other.
6. A multistage dual axis four quadrant area concentrator for CPV as claimed in claim 1 , wherein the reflecting surface includes at least one from glass, metal, polymers or synthetic materials and / or combination of any of these materials.
7. A multistage dual axis four quadrant area concentrator for CPV as claimed in claim 1 , wherein the said primary concentrator and collector concentrators are piece wised parabolic and conical reflectors.
8. A multistage dual axis four quadrarit area concentrator for CPV as claimed in claim 1 , wherein the reflective surfaces are secured with velcro tapes for easy repair / replacement.
9. A multistage dual axis four quadrant area concentrator for CPV as claimed in claim 1 , wherein the assembly is installed over a movable stand configured for tracking the sun in real time.
10. A multistage dual axis four quadrant area concentrator for CPV as claimed in claim 1 , wherein the said primary concentrator, collector concentrators and the receiver concentrator are positioned in relation with each other so that during operation the solar insolance falling on the primary concentrator is reflected to the collector concentrators and gets concentrated multiple times before hitting the surface of the receiver concentrator thereby increasing the output power by multiple times.
1 1. A multistage dual axis four quadrant area concentrator for CPV as claimed in any of the preceding claims wherein the said assembly is scalable and adaptable to the available solar panels with customization for thermal management and current handling capabilities.
12. A multistage dual axis four quadrant area concentrator for CPV as claimed in any of the preceding claims wherein the said concentrator is configured for collection of solar insolence in pen umbra regions and focusing it to the receiver by keeping high collector concentration levels and allow tolerances for sun tracking for best concentration properties.
13. A method for assembly of multistage dual axis four quadrant area concentrator for CPV comprising of:
laying and configuring a primary parabolic reflective concentrator with aperture aligned to focus the orthogonally incoming collimated solar insolence toward a focal point f(p); positioning at least one collector concentrator, which is essentially a feed reflective conical aperture concentrator with a focal point f(c); positioning a receiver concentrator, which is an array of photovoltaic cells, placed over a conical surface and positioned with a focal point f(r), which is measured from the focal point of the collector concentrator (f(p)) and is configured to receive the multistage concentrated solar insolence from the collector concentrator; wherein the primary concentration levels are achieved by the ratio of f(p)/f(c) which is also the ratio of the linear dimensions of the primary concentrator and collector concentrator; wherein the position of the collector concentrator is f(p) + f(c); and wherein the area concentration ratio is adjustable.
14. A method for assembly of a multistage dual axis four quadrant area concentrator for CPV as claimed in claim 13, wherein the primary parabolic reflective concentrator has a dimension larger than the largest dimension of the collector concentrator.
15. A method for assembly of a multistage dual axis four quadrant area concentrator for CPV as claimed in claim 13, wherein the aperture of the primary and collector concentrator face each other with their focal line and axes coincides with each other.
16. A method for assembly of a multistage dual axis four quadrant area concentrator for CPV as claimed in claim 13, wherein the area concentration ratio can be adjusted by adjusting the ratio [f(p)/f(c)J and [f(c)/f(r)J.
17. A method for assembly of a multistage dual axis four quadrant area concentrator for CPV as claimed in claim 13, wherein the collector concentrator is subdivided into plurality of collector concentrators facing each other and their focal axes coincide each other.
18. A method for assembly of a multistage dual axis four quadrant area concentrator for CPV as claimed in claim 13, wherein the reflecting surface includes at least one from glass, metal, polymers or synthetic materials and / or combination of any of these materials.
19. A method for assembly of a multistage dual axis four quadrant area concentrator for CPV as claimed in claim 13. wherein the said primary concentrator and collector concentrators are piece wised parabolic and conical reflectors
20. A method for assembly of a multistage dual axis four quadrant area concentrator for CPV as claimed in claim 13, wherein the reflective surfaces are secured with velcro tapes for easy repair / replacement.
21. A method for assembly of a multistage dual axis four quadrant area concentrator for CPV as claimed in claim 13, wherein the assembly is installed over a movable stand configured for tracking the sun in real time.
22. A method for assembly of a multistage dual axis four quadrant area concentrator for CPV as claimed in claim 13, wherein the said primary concentrator, collector concentrators and the receiver concentrator are positioned in relation with each other so that during operation the solar insolence falling on the primary concentrator is reflected to the collector concentrators and gets concentrated multiple times before hitting the surface of the receiver concentrator thereby increasing the output power by multiple times.
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