Reflective concentrating solar cell assembly

• US 6,008,449 A
• Filed: 08/19/1997
• Issued: 12/28/1999
• Est. Priority Date: 08/19/1997
• Status: Expired due to Term

• Current Assignee: Eric Cole
• Original Assignee: Daystar Technologies, Inc.
• Inventors: Cole, Eric D.
• Primary Examiner(s): CHAPMAN, MARK A
• Application Number:
  US08/914,323
• Time in Patent Office: 861 Days
• Field of Search: 136/246
• US Class Current: 136/246
• CPC Class Codes: H01L 31/048 Encapsulation of modules
• CPC Class Codes: H01L 31/0508 the interconnection means having a particular shape
• CPC Class Codes: H01L 31/0547 comprising light concentrating means of the reflecting type, e.g. parabolic mirrors, concentrators using total internal reflection
• CPC Class Codes: Y02E 10/52 PV systems with concentrators

Abstract

A solar cell assembly for focusing incident radiation on a solar cell. The assembly comprises a reflective member having first and second opposite surfaces. The first surface is transparent to allow incident radiation to pass into the reflective member. The second surface has a plurality of reflective portions positioned to receive the radiation and reflect and focus the radiation toward the first surface. The radiation strikes the first surface at an angle greater than a critical angle of the first surface and is reflected and focused back toward the second surface. The assembly further comprises a solar cell positioned at least proximate to the reflective member to receive the radiation reflected and focused from the first surface of the reflective member and generate electric current from the radiation.

Claims

1. A solar cell assembly, comprising:

a reflective member having first and second opposite surfaces, the first surface being substantially transparent, the second surface having a transparent portion and a plurality of opaque reflective portions, neighboring reflective portions being canted at least partially toward each other to receive radiation passing through the first surface of the reflective member and focus and reflect the radiation to form focused radiation directed toward the first surface at an angle relative to the first surface greater than a critical angle of the first surface, the first surface being positioned to direct the focused radiation away from the first surface, the focused radiation converging as it moves away from the first surface; and

a solar cell having a radiation receiving surface affixed to the transparent portion of the second surface of the reflective member and positioned to receive the focused radiation.

2. The assembly of claim 1 wherein the reflective member comprises:

a support layer having first and second opposite surfaces, the first surface of the reflective member comprising the second surface of the support layer; and

a film layer having first and second opposite surfaces, the first surface of the film layer being bonded to the first surface of the support layer, the second surface of the reflective member comprising the second surface of the film layer, wherein each opaque reflective portion of the reflective member includes a reflective metallic layer positioned to direct a portion of the focused radiation through the film layer and the support layer toward the second surface of the support layer without striking another reflective portion.

3. The assembly of claim 1 wherein the reflective member comprises:

a support layer having first and second opposite surfaces, the first surface of the reflective member comprising the second surface of the support layer; and

a film layer having first and second opposite surfaces, the first surface of the film layer being bonded to the first surface of the support layer and forming the second surface of the reflective member.

4. The assembly of claim 1 wherein each reflective portion of the reflective member is positioned to direct the focused radiation toward the first surface without striking another reflective portion.

5. The assembly of claim 1 wherein the solar cell has first and second spaced apart ends and is elongated along a longitudinal axis extending between the ends, and the reflective portions are elongated substantially parallel to the longitudinal axis.

6. The assembly of claim 1 wherein the solar cell has a substantially circular shape and the reflective portions extend concentrically around the solar cell.

7. The assembly of claim 1 wherein the radiation receiving surface of the solar cell has first and second spaced apart edges and a central region intermediate the edges, the focused radiation impinging on the central portion of radiation receiving surface.

8. The assembly of claim 1 wherein the solar cell is a first solar cell, the plurality of opaque reflective portions is a first plurality, the radiation comprises a first radiation portion and the focused radiation is a first focused radiation portion, further comprising:

a second plurality of opaque reflective portions positioned to receive a second radiation portion passing through the first surface of the reflective member and focus and reflect the second radiation portion to form a second focused radiation portion directed toward the first surface at an angle relative to the first surface greater than a critical angle of the first surface. the first surface being positioned to direct the second focused radiation portion away from the first surface, radiation of the second focused radiation portion converging as it moves away from the first surface; and

a second solar cell having a radiation receiving surface bonded to a second transparent portion of the second surface of the reflective member and positioned to receive the second focused radiation portion.

9. The assembly of claim 1 wherein the reflective member comprises acrylic and the solar cell is a first solar cell, the plurality of opaque reflective portions is a first plurality, the radiation comprises a first radiation portion and the focused radiation is a first focused radiation portion, further comprising:

a second plurality of opaque reflective portions positioned to receive a second radiation portion passing through the first surface of the reflective member and focus and reflect the second radiation portion to form a second focused radiation portion directed toward the first surface at an angle relative to the first surface greater than a critical angle of the first surface, the first surface being positioned to direct the second focused radiation portion away from the first surface, radiation of the second focused radiation portion converging as it moves away from the first surface; and

a second solar cell having a radiation receiving surface bonded to a second transparent portion of the second surface of the reflective member and positioned to receive the second focused radiation portion, the second solar cell being spaced apart from the first solar cell by a distance in the range of approximately 1.8 to 2.22 times a thickness of the reflective member.

10. The assembly of claim 1 wherein the solar cell is a first solar cell, the plurality of opaque reflective portions is a first plurality, the radiation comprises a first radiation portion and the focused radiation is a first focused radiation portion, further comprising:

a second plurality of opaque reflective portions positioned to receive a second radiation portion passing through the first surface of the reflective member and focus and reflect the second radiation portion to form a second focused radiation portion directed toward the first surface at an angle relative to the first surface greater than a critical angle of the first surface, the first surface being positioned to direct the second focused radiation portion away from the first surface, radiation of the second focused portion converging as it moves away from the first surface; and

a second solar cell having a radiation receiving surface bonded to a second transparent portion of the second surface of the reflective member and positioned to receive the second focused radiation portion, the second solar cell being spaced apart from the first solar cell by a distance approximately equal to 1.0 to 2.22 times a thickness of the reflective member.

11. The assembly of claim 1 wherein the solar cell is a first solar cell, the plurality of opaque reflective portions is a first plurality, the radiation comprises a first radiation portion and the focused radiation is a first focused radiation portion, further comprising:

a second plurality of opaque reflective portions positioned to receive a second radiation portion passing through the first surface of the reflective member and focus and reflect the second radiation portion to form a second focused radiation portion directed toward the first surface at an angle relative to the first surface greater than a critical angle of the first surface, the first surface being positioned to direct the second focused radiation portion away from the first surface, radiation of the second focused portion converging as it moves away from the first surface; and

a second solar cell having a radiation receiving surface bonded to a second transparent portion of the second surface of the reflective member and positioned to receive the second focused radiation portion, each of the first plurality of reflective portions comprising a reflective metallic layer positioned to direct the first portion of the focused radiation through the reflective member toward the first surface, adjacent metallic layers being electrically coupled to each other to form a continuous conductive layer extending between the first and second solar cells, the first and second solar cells being electrically coupled to the conductive layer.

12. The assembly of claim 1 wherein the reflective member comprises an acrylic material.

13. The assembly of claim 1 wherein the reflective member comprises glass.

14. The assembly of claim 1 wherein the radiation receiving surface of the solar cell is substantially flat.

15. The assembly of claim 1 wherein the radiation receiving surface of the solar cell is convex, having first and second spaced apart edges and a central region intermediate the edges, the first surface of the reflective member being positioned closer to the central region of the solar cell than to the edges thereof.

16. The assembly of claim 1 wherein the radiation receiving surface of the solar cell is concave, having first and second spaced apart edges and a central region intermediate the edges, the first surface of the reflective member being positioned further from the central region of the solar cell than to the edges thereof.

17. The assembly of claim 1 wherein the solar cell is a first solar cell and the radiation comprises a first radiation portion, further comprising second, third and fourth solar cells, and wherein the plurality of opaque reflective portions includes a first reflective portion positioned to reflect the first portion of radiation toward the first solar cell, a second reflective portion facing opposite the first reflective portion and positioned to reflect a second portion of radiation toward the second solar cell, a third reflective portion positioned intermediate the first and second reflective portions to reflect a third portion of radiation toward the third solar cell, and a fourth reflective portion facing opposite the third reflective portion to reflect a fourth portion of radiation toward the fourth solar cell.

18. The assembly of claim 17 wherein the first, second, third and fourth reflective portions each have a triangular shape, the reflective portions being joined at a common point to form a pyramidal reflective element.

19. The assembly of claim 17 wherein at least one of the reflective portions has a flat surface.

20. The assembly of claim 17 wherein at least one of the reflective portions has a curved surface.

21. The assembly of claim 17 wherein the reflective portions together comprise a first reflective element and the solar cells together comprise a first solar cell group, the first solar cell group having a first diagonal axis extending from the reflective element between the first and third solar cells and a second diagonal axis extending from the reflective element between the second and third solar cells, further comprising a second reflective element and second solar cell group adjacent the first reflective element and first solar cell group, respectively, the second reflective element positioned on one of the first and second diagonal axes.

22. A solar cell assembly, comprising:

a reflective member having first and second opposite surfaces, the first surface being at least partially transparent, the second surface having a plurality of reflective portions, neighboring reflective portions being positioned to receive radiation passing through the first surface of the reflective member and converge and reflect the radiation to form converged radiation directed toward the first surface at an angle relative to the first surface greater than a critical angle of the first surface, the first surface being positioned to direct the converged radiation away from the first surface, the converged radiation converging as it moves away from the first surface; and

a solar cell positioned at least proximate to the reflective member, the solar cell having a radiation receiving surface positioned to receive the converged radiation directed away from the first surface and generate an electrical current therefrom.

23. The assembly of claim 22 wherein the reflective member comprises:

a support layer having first and second opposite surfaces, the first surface of the reflective member comprising the second surface of the support layer; and

a film layer having first and second opposite surfaces, the first surface of the film layer being bonded to the first surface of the support layer, the second surface of the reflective member comprising the second surface of the film layer, wherein each reflective portion of the reflective member includes a reflective metallic layer positioned to direct a portion of the converged radiation through the film layer and the support layer toward the second surface of the support layer without striking another reflective portion.

24. The assembly of claim 22 wherein each reflective portion of the reflective member is positioned to direct the converged radiation toward the first surface without striking another reflective portion.

25. The assembly of claim 22 wherein the solar cell is a first solar cell, the plurality of reflective portions is a first plurality, the radiation comprises a first radiation portion, and the converged radiation is a first converged radiation portion, further comprising:

a second plurality of reflective portions positioned to receive a second radiation portion passing through the first surface of the reflective member and converge and reflect the second radiation portion to form a second converged radiation portion directed toward the first surface at an angle relative to the first surface greater than a critical angle of the first surface, the first surface being positioned to direct the second converged radiation portion away from the first surface by total internal reflection, radiation of the second converged radiation portion converging as it moves away from the first surface; and

a second solar cell positioned at least proximate to the reflective member, the second solar cell having a radiation receiving surface positioned to receive the second converged radiation portion and generate an electrical current therefrom.

26. The assembly of claim 22 wherein the solar cell is a first solar cell, the plurality of reflective portions is a first plurality, the radiation comprises a first radiation portion and the converged radiation is a first converged radiation portion, further comprising:

a second plurality of reflective portions positioned to receive a second radiation portion passing through the first surface of the reflective member and converge and reflect the second radiation portion to form a second converged radiation portion directed toward the first surface at an angle relative to the first surface greater than a critical angle of the first surface, the first surface being positioned to direct the second converged radiation portion away from the first surface, radiation of the second converged radiation portion converging as it moves away from the first surface; and

a second solar cell having a radiation receiving surface bonded to a second transparent portion of the second surface of the reflective member and positioned to receive the second converged radiation portion, each of the first plurality of reflective portions comprising a reflective metallic layer positioned to direct the first portion of the converged radiation through the reflective member toward the first surface, adjacent metallic layers being electrically coupled to each other to form a continuous conductive layer extending between the first and second solar cells, the first and second solar cells being electrically coupled to the conductive layer.

27. The assembly of claim 22 wherein the solar cell is a first solar cell and the radiation comprises a first radiation portion, further comprising second and third solar cells, and wherein the plurality of reflective portions includes a first reflective portion positioned to reflect the first portion of radiation toward the first solar cell, a second reflective portion facing opposite the first reflective portion and positioned to reflect a second portion of radiation toward the second solar cell, the first and second solar cells defining an axis extending therebetween, the reflective portions further including a third reflective portion positioned intermediate the first and second reflective portions to reflect a third portion of radiation toward the third solar cell, the third solar cell being offset from the axis extending between the first and second solar cells.

28. A solar cell assembly, comprising:

a solar cell having a radiation receiving surface positioned to receive radiation and generate electrical current therefrom;

a reflective layer having a substantially transparent first surface and a second surface opposite the first, the second surface having a bonding portion bonded to the radiation receiving surface of the solar cell, and a plurality of spaced apart reflective portions, neighboring reflective portions positioned to receive a portion of radiation passing through the reflective layer from the first surface to the second surface and reflectively redirect the radiation portion along a reflected path extending away from the second surface, the reflected paths approaching each other as they extend away from the second surface; and

a substantially transparent support layer having a first surface bonded to the first surface of the reflective layer and a second surface opposite the first, the support layer having an index of reffaction sufficient to receive the radiation portions reflected from the reflective layer and redirect by total internal reflection the radiation portions along redirected paths extending away from the first surface toward solar cell, the redirected paths approaching each other as they extend away from the first surface.

29. The assembly of claim 28 wherein the reflective member comprises:

a support layer having first and second opposite surfaces, the first surface of the reflective member comprising the second surface of the support layer; and

a film layer having first and second opposite surfaces, the first surface of the film layer being bonded to the first surface of the support layer and forming the second surface of the reflective member.

30. The assembly of claim 28 wherein the reflective layer is bendable in a direction normal to the first surface thereof and the support layer is substantially rigid in a direction normal to the first surface thereof and is adhesively bonded to the reflective layer to restrict bending of the reflective layer in the direction normal to the first surface of the reflective layer, each reflective portion of the reflective layer comprising a reflective metallic layer positioned to reflect radiation from the reflective portion through the reflective layer and the support layer, each reflective portion being positioned to redirect the radiation portion along the corresponding reflected path without striking another reflective portion.

31. The assembly of claim 28, further comprising an adhesive layer positioned between the support layer and the reflective layer to bond the support layer and reflective layer together, the adhesive layer having an index of refraction substantially equal to an index of refraction of the support layer.

32. The assembly of claim 28, further comprising an adhesive layer positioned between the support layer and the reflective layer to bond the support layer and reflective layer together, the adhesive layer having an index of refraction substantially equal to an index of refraction of the reflective layer.

33. The assembly of claim 28 wherein the reflective layer has an index of refraction substantially equal to an index of refraction of the support layer.

34. The assembly of claim 28 wherein the reflective layer comprises an acrylic material and the support layer comprises glass.

35. A solar cell assembly, comprising:

a solar cell having a radiation receiving surface positioned to receive radiation and generate electrical current therefrom;

a reflective layer having a substantially transparent first surface and a second surface opposite the first, the second surface having a bonding portion bonded to the radiation receiving surface of the solar cell and a plurality of spaced apart reflective portions, neighboring reflective portions positioned to receive a portion of radiation passing through the reflective layer from the first surface to the second surface and reflectively redirect radiation portion along a reflected path extending away from the second surface, the reflected paths approaching each other as they extend away from the second surface, the first surface of the reflective layer having an index of refraction sufficient to receive the radiation portions reflected from the second surface thereof and redirect the radiation portions by total internal reflection toward the solar cell, the radiation portions converging as they move away from the first surface.

36. The assembly of claim 35 wherein the reflective portions each comprise a reflective metallic layer positioned to reflect radiation from the reflective portions through the reflective member toward the first surface, each reflective portion being positioned to redirect the radiation portion along the corresponding reflected path without striking another reflective portion.

37. A solar cell assembly, comprising:

first and second spaced apart solar cells, each having a radiation receiving surface; and

a reflective member having first and second opposite surfaces, the first surface being substantially transparent, the second surface having first and second transparent portions bonded to the radiation receiving surfaces of the first and second solar cells, respectively, the second surface further having a plurality of opaque reflective units, each reflective portion having a first facet and an adjacent second facet,

each of the first facets having a different angular orientation relative to the first surface to collectively receive a first portion of radiation passing through the first surface of the reflective member and reflectively focus and redirect the first portion of radiation toward the first surface at an angle relative to the first surface greater than a critical angle of the first surface, the first surface being positioned to direct the first radiation portion away from the first surface toward the first solar cell, the first radiation portion converging as it moves away from the first surface,

each of the second facets having a different angular orientation relative to the first surface to collectively receive a second portion of radiation passing through the first surface of the reflective member and reflectively focus and redirect the second portion of radiation toward the first surface at an angle relative to the first surface greater than a critical angle of the first surface, the first surface being positioned to direct the second radiation portion away from the first surface toward the second solar cell, the second radiation portion converging as it moves away from the first surface.

38. A reflective assembly for focusing radiation, comprising:

a reflective member having first and second opposite surfaces, the first surface being at least partially transparent, the second surface having a plurality of reflective portions, neighboring reflective portions being canted at different angles relative to the first surface to receive radiation passing through the first surface of the reflective member and focus and reflect the radiation to form focused radiation directed toward the first surface at an angle relative to the first surface greater than a critical angle of the first surface, the first surface being positioned to direct the focused radiation away from the first surface, the focused radiation converging as it moves away from the first surface.

39. A method for focusing radiation on a radiation receiving surface of a solar cell, comprising:

directing the radiation through a substantially transparent first surface of a reflective member toward a second surface of the reflective member opposite the first surface;

reflecting a first portion of the radiation away from a first opaque portion of the second surface to form a first portion of reflected radiation directed toward the first surface;

reflecting a second portion of the radiation away from a second opaque portion of the second surface adjacent the first portion to form a second portion of reflected radiation directed toward the first surface and toward the first portion of reflected radiation; and

reflecting the first and second reflected radiation portions at the first surface to direct the reflected radiation portions toward each other and toward the receiving surface of the solar cell.

40. The method of claim 39 wherein the act of reflecting the first portion of the radiation includes directing the first portion of reflected radiation toward the first surface at an angle greater than a critical angle of the first surface.

41. The method of claim 39 wherein the act of reflecting the second portion of the radiation includes directing the second portion of reflected radiation toward the first surface at an angle greater than a critical angle of the reflective member.

42. The method of claim 39, further comprising selecting a thickness of the reflective member to direct the first and second portions of reflected radiation to impinge at substantially the same location on the radiation receiving surface of the solar cell.

43. The method of claim 39, further comprising selecting a thickness of the reflective member to direct the first and second portions of reflected radiation to impinge on the radiation receiving surface of the solar cell at first and second spaced apart locations, respectively.

44. The method of claim 39, further comprising selecting a thickness of the reflective member to focus the first and second reflected radiation portions by a desired amount on the receiving surface of the solar cell.

45. The method of claim 39 wherein the act of reflecting the second portion of the radiation includes preventing the second portion of reflected radiation from impinging on the first opaque portion.