Apparatus and method for producing AC power

• US 9,391,457 B2
• Filed: 09/28/2012
• Issued: 07/12/2016
• Est. Priority Date: 10/07/2008
• Status: Active Grant

• Current Assignee: Sunlight Aerospace Incorporated
• Original Assignee: Sunlight Photonics Incorporated
• Inventors: Frolov, Sergey, Bruce, Allan James, Cyrus, Michael
• Primary Examiner(s): Fleming, Fritz M
• Application Number:
  US13/631,158
• Publication Number:
  US 20130043733A1
• Time in Patent Office: 1,383 Days
• Field of Search: 307/77, 307/82, 307/84
• US Class Current: 1/1
• CPC Class Codes: H01L 31/02021 for solar cells electrical connection means, e.g. junction boxes, specially adapted for structural association with photovoltaic modules H02S40/34
• CPC Class Codes: H01L 31/02366 of the substrate or of a layer on the substrate, e.g. textured ITO/glass substrate or superstrate, textured polymer layer on glass substrate
• CPC Class Codes: H01L 31/0687 Multiple junction or tandem solar cells
• CPC Class Codes: H01L 31/076 Multiple junction or tandem solar cells
• CPC Class Codes: H02J 2300/24 of photovoltaic origin
• CPC Class Codes: H02J 3/381 Dispersed generators
• CPC Class Codes: H02J 3/40 Synchronising a generator for connection to a network or to another generator
• CPC Class Codes: Y02B 10/10 Photovoltaic [PV]
• CPC Class Codes: Y02E 10/544 Solar cells from Group III-V materials
• CPC Class Codes: Y02E 10/548 Amorphous silicon PV cells
• CPC Class Codes: Y02E 10/56 Power conversion systems, e.g. maximum power point trackers
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product

Abstract

A multi-input electrical power conversion device is provided for converting multiple DC energies each arising from different junctions in a multi-junction solar cells into AC energy. The device includes a plurality of electrical inputs for receiving the multiple DC energies from at least one multi junction solar cell. The number of DC energies id no less than the number of junctions in the multi-junction solar cell. The device also includes at least one DC-to-AC circuit for receiving the multiple DC energies from the plurality of electrical inputs and at least one electrical output receiving at least one AC energy from the DC to AC circuit. The device also includes at least one MPPT circuit operatively coupled to the DC to AC circuit.

Claims

1. A multi-input electrical power conversion device for converting multiple DC energies each arising from different junctions in a multi junction solar cell into AC energy, comprising:

a plurality of electrical input pairs for receiving the multiple DC energies from at least one multi junction solar cell, each of the electrical input pairs being in physical contact with a pair of electrical contacts in the multi-junction solar cell between which one of the junctions is located;

a plurality of DC-to-AC inverting circuits each for receiving the DC energy from a different one of the plurality of electrical input pairs, each of the DC-to-AC inverting circuits having a pair of inputs that physically contact one of the electrical input pairs that receive the DC energy;

at least one electrical output receiving at least one AC energy from the plurality of DC to AC inverting circuits;

at least one MPPT circuit operatively coupled to the DC to AC inverting circuits;

a package housing the plurality of electrical input pairs, the plurality of DC-to-AC inverting circuits, the at least one electrical output and the at least one MPPT circuit.

2. The electrical power conversion device of claim 1 further comprising an AC disconnect switch for disconnecting the electrical output under control of the MPPT circuit.

3. The electrical power conversion device of claim 1 further comprising at least one DC to DC circuit coupling the electrical inputs to the plurality of DC-AC inverting circuits.

4. The electrical power conversion device of claim 3 further comprising a number of said DC-to-DC inverting circuits that is equal to the number of said DC energies.

5. The electrical power conversion device of claim 1 further comprising a number of said DC-to-AC inverting circuits that is equal to the number of said DC energies.

6. The electrical power conversion device of claim 1 further comprising a number of said MPPT circuits that is equal to the number of said DC energies.

7. The electrical power conversion device of claim 1 further comprising a carrier configured to support the package on a first side thereof and to support the multi junction solar cell on a second side thereof opposing the first side.

8. The electrical power conversion device of claim 7 wherein the package has a flat form factor having a thickness that is less than its length and width.

9. The electrical power conversion device of claim 1 wherein the plurality of electrical input pairs receive the multiple DC energies from a single multi junction solar cell.

10. The electrical power conversion device of claim 1 further comprising a controller operative coupled to each of the DC-AC inverting circuits, the controller including the at least one MPPT circuit.

11. The electrical power conversion device of claim 10 further comprising a plurality of sensors each monitoring one of the electrical input pairs, the sensors being operatively coupled to the controller.

12. The electrical power conversion device of claim 1 wherein the DC-to-AC inverting circuits are each differently configured for receipt of different input powers and/or voltages.

13. The electrical power conversion device of claim 1 wherein the at least one multi-junction solar cell includes a plurality of multi junction solar cells serially interconnected with one another.

14. The electrical power conversion device of claim 1 wherein the at least one multi-junction solar cell includes a first plurality of multi junction solar cells serially interconnected with one another and a second plurality of multi junction solar cells serially interconnected with one another such that the multi junction solar cells in the first plurality of multi junction solar cells are not serially interconnected with the multi junction solar cells in the second plurality of multi junction solar cells.

15. An AC photovoltaic module comprising:

at least one multi junction solar cell having at least two pairs of DC electrical outputs each associated with a different junction in the multi junction solar cell, each of said DC electric output pairs receiving DC electrical energy from the junction with which it is associated;

a multi-input electrical power conversion device, said multi junction electrical power conversion device also including a plurality of DC-to-AC circuits and at least one MPPT circuit, each of the DC-to-AC circuits being in physical contact with one of the pairs of DC electrical outputs to receive the DC electrical energy therefrom;

at least one electrical output receiving at least one AC energy from the electrical power conversion device.

16. The photovoltaic AC module of claim 15 wherein the multi-input electrical power conversion device further comprises at least two DC to DC circuits.

17. The photovoltaic AC module of claim 15 further comprising a carrier for supporting the solar cells and the multi-input electrical power conversion device.

18. The photovoltaic AC module of claim 17 further comprising a frame surrounding the carrier.

19. The photovoltaic AC module of claim 18 wherein said multi-input electrical power conversion device is attached to said frame.

20. The photovoltaic AC module of claim 17 wherein said multi-input electrical power conversion device is electrically and mechanically connectable to and disconnectable from said carrier.

21. The photovoltaic AC module of claim 17 wherein the carrier is adapted to be integrated into at least one component of a building selected from the group consisting of a roof, walls, doors and windows.

22. The photovoltaic AC module of claim 15 wherein said multi-input electrical power conversion device is detachable from a remainder of said module.

23. The photovoltaic AC module of claim 15 wherein said at least one multi-junction solar cell comprises at least two strings of photovoltaic cells.

24. The photovoltaic AC module of claim 15 wherein said plurality of DC electrical outputs is three DC electrical outputs.

25. A multi-input electrical power conversion device for converting multiple DC energies each arising from different junctions in a multi junction solar cell into AC energy, comprising:

a plurality of electrical input pairs for receiving the multiple DC energies from at least one multi junction solar cell;

a plurality of DC-to-DC converters each for receiving the DC energy from a different one of the plurality of electrical input pairs, the DC energies being converted to a common DC energy;

a common DC-to-AC inverting circuit having an input pair for receiving the common DC energies from the plurality of DC-to-DC converters;

at least one electrical output receiving at least one AC energy from the plurality of DC to AC inverting circuits; and

a controller operative coupled to each of the DC-DC inverting circuits and the common DC-to-AC inverting circuit, the controller including a MPPT circuit.

26. The electrical power conversion device of claim 25 further comprising a first plurality of sensors each monitoring one of the electrical input pairs, the first plurality of sensors being operatively coupled to the controller.

27. The electrical power conversion device of claim 26 a second plurality of sensors each monitoring a pair of outputs from one of the DC-to-DC converters, the second plurality of sensors being operatively coupled to the controller.

28. The electrical power conversion device of claim 27 wherein the controller is configured to independently control each of DC-to-DC converters in a closed-loop control manner.

29. The electrical power conversion device of claim 27 further comprising a third sensor monitoring the common DC energies received by the input pair of the common DC-to-AC inverting circuit, the third sensor being operatively coupled to the controller.

30. The electrical power conversion device of claim 29 further comprising a fourth sensor monitoring the at least one electrical output from the common DC to AC inverting circuit, the fourth sensor being operatively coupled to the controller.