U.S. patent number RE48,808 [Application Number 16/556,003] was granted by the patent office on 2021-11-02 for high accuracy module assembly process.
This patent grant is currently assigned to Saint-Augustin Canada Electric Inc.. The grantee listed for this patent is Saint-Augustin Canada Electric Inc.. Invention is credited to Rainer Krause, Eric Mazaleyrat.
United States Patent |
RE48,808 |
Krause , et al. |
November 2, 2021 |
High accuracy module assembly process
Abstract
The present invention relates to an assembling method for a base
plate of a concentrated photovoltaic module comprising the steps
of: assembling a heat sink on the base plate; and assembling a
photovoltaic cell assembly on the heat sink after the heat sink has
been assembled on the base plate.
Inventors: |
Krause; Rainer (Mainz-Kostheim,
DE), Mazaleyrat; Eric (Crolles, FR) |
Applicant: |
Name |
City |
State |
Country |
Type |
Saint-Augustin Canada Electric Inc. |
Saint-Augustin de Desmaures |
N/A |
CA |
|
|
Assignee: |
Saint-Augustin Canada Electric
Inc. (Saint-Augustin de Desmaures, CA)
|
Family
ID: |
48570369 |
Appl.
No.: |
16/556,003 |
Filed: |
August 29, 2019 |
PCT
Filed: |
March 26, 2014 |
PCT No.: |
PCT/EP2014/056091 |
371(c)(1),(2),(4) Date: |
September 28, 2015 |
PCT
Pub. No.: |
WO2014/154768 |
PCT
Pub. Date: |
October 02, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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Reissue of: |
14780752 |
Mar 26, 2014 |
9748420 |
Aug 29, 2017 |
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Foreign Application Priority Data
|
|
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Mar 29, 2013 [FR] |
|
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1352870 |
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01L
31/052 (20130101); H01L 31/0543 (20141201); H01L
31/024 (20130101); Y02E 10/52 (20130101) |
Current International
Class: |
H01L
31/0232 (20140101); H01L 31/024 (20140101); H01L
31/054 (20140101); H01L 31/052 (20140101); H01L
31/0236 (20060101) |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Other References
International Search Report for International Application No.
PCT/EP2014/056091, dated May 26, 2014, 3 pages. cited by applicant
.
International Written Opinion for International Application No.
PCT/EP2014/056091, dated May 26, 2014, 3 pages. cited by applicant
.
International Search Report for International Application No.
PCT/EP2014/056091 dated Apr. 28, 3014, 3 pages. cited by applicant
.
French Preliminary Search Report for French Application No. 1352870
dated Oct. 211, 2013, 8 pages. cited by applicant .
Chinese Office Action and Search Report for Chinese Application No.
201480024029.1 dated Jun. 29, 2016, 6 pages. cited by applicant
.
Written Opinion of the International Searching Authority for
International Application No. PCT/EP2014/056091 dated Apr. 28,
3014, 3 pages. cited by applicant .
International Preliminary Report on Patentability for International
Application No. PCT/EP2014/056091 dated Sep. 29, 2015, 4 pages.
cited by applicant.
|
Primary Examiner: Xu; Ling X
Attorney, Agent or Firm: TraskBritt
Claims
The invention claimed is:
1. A method comprising the steps of: assembling a heat sink on a
base plate of a concentrated photovoltaic module; and assembling a
photovoltaic cell assembly on the heat sink after the heat sink has
been assembled on the base plate; wherein the method further
comprises a step of marking the heat sink, once assembled on the
base plate, with position markings indicating a mounting position
of the photovoltaic cell assembly; wherein the step of assembling
the photovoltaic cell assembly on the heat sink is carried out by
using the position markings for the alignment of the photovoltaic
cell assembly.
2. The method according to claim 1, wherein the photovoltaic cell
assembly comprises a photovoltaic cell.
3. The method according to claim 2, wherein the photovoltaic cell
assembly further comprises a semiconductor structure on which the
photovoltaic cell is assembled.
4. The method according to claim 3, further comprising the step of
assembling the photovoltaic cell on the semiconductor structure
with a semiconductor manufacturing process.
5. The method according to claim 4, wherein the step of marking the
heat sink comprises marking the heat sink with position markings
based on a position of a lens of the concentrated photovoltaic
module.
6. The method according to claim 5, wherein the position marking is
obtained by a laser.
7. The method according to claim 5, wherein the position of a lens
is determined with respect to a common reference point between a
lenses layer and the base plate.
8. The method according to claim 7, wherein the assembling of the
photovoltaic cell assembly on the heat sink is realized by means of
gluing and/or laser welding.
9. The method according to claim 1, wherein the step of marking the
heat sink comprises marking the heat sink with position markings
based on a position of a lens of the concentrated photovoltaic
module.
10. The method according to claim 3, wherein the step of marking
the heat sink comprises marking the heat sink with position
markings based on a position of a lens of the concentrated
photovoltaic module.
11. The method according to claim 1, wherein the assembling of the
photovoltaic cell assembly on the heat sink is realized by means of
gluing and/or laser welding.
.Iadd.12. A method of aligning a photovoltaic cell assembly with a
heat sink, the method comprising: assembling a heat sink on a base
plate of a concentrated photovoltaic module; marking the heat sink
with position markings indicating a mounting position of the
photovoltaic cell assembly; and assembling the photovoltaic cell
assembly on the heat sink using the position markings for alignment
of the photovoltaic cell assembly..Iaddend.
.Iadd.13. A concentrated photovoltaic module, comprising: a heat
sink supported on a base plate; a photovoltaic cell assembly
supported on the heat sink; and a lens supported over the
photovoltaic cell assembly; wherein the heat sink comprises at
least one position marking aligned with the photovoltaic cell
assembly, the at least one position marking indicating a mounting
position of the photovoltaic cell assembly on the heat
sink..Iaddend.
.Iadd.14. The concentrated photovoltaic module of claim 13, wherein
the at least one position marking comprises: a first position
marking having a corner shape, the corner shape of the first
position marking aligned with two sides of the photovoltaic cell
assembly; and a second position marking having a cross shape, the
cross shape of the second position marking underlying the
photovoltaic cell assembly..Iaddend.
.Iadd.15. The concentrated photovoltaic module of claim 13, wherein
the photovoltaic cell assembly comprises a photovoltaic cell
supported on a semiconductor structure, the semiconductor structure
comprising one or more of a bypass diode and all necessary
electrical connections for the photovoltaic cell..Iaddend.
.Iadd.16. The concentrated photovoltaic module of claim 15, wherein
a tolerance for placement of the photovoltaic cell assembly on the
heat sink is in a range of micrometers or lower..Iaddend.
.Iadd.17. The concentrated photovoltaic module of claim 13, wherein
the photovoltaic cell assembly is affixed to the heat sink by glue
or a weld..Iaddend.
.Iadd.18. The concentrated photovoltaic module of claim 13, wherein
the heat sink is affixed to the base plate by glue, a weld, or
screws..Iaddend.
.Iadd.19. The concentrated photovoltaic module of claim 13, wherein
the lens comprises one or more transparent, nonfocusing
regions..Iaddend.
.Iadd.20. The concentrated photovoltaic module of claim 19, wherein
the one or more transparent, nonfocusing regions are aligned with
the at least one position marking of the heat sink..Iaddend.
.Iadd.21. The concentrated photovoltaic module of claim 13, wherein
the lens is configured to focus all incoming light in a region
corresponding to placement of the photovoltaic cell assembly on the
heat sink..Iaddend.
.Iadd.22. The concentrated photovoltaic module of claim 13, wherein
the lens is configured to vertically focus rays going through a
center of the lens..Iaddend.
.Iadd.23. The concentrated photovoltaic module of claim 13, wherein
a focal distance of the lens at wavelengths for a laser corresponds
to a top plane of the heat sink and the focal distance of the lens
at wavelengths for sunlight corresponds to a top plane of the
photovoltaic cell assembly..Iaddend.
.Iadd.24. An intermediate product in a process of forming a
concentrated photovoltaic module, comprising: a heat sink supported
on a base plate; wherein the heat sink comprises at least one
position marking indicating a mounting position for a photovoltaic
cell assembly on the heat sink; and wherein the heat sink lacks a
photovoltaic cell assembly supported on the heat sink, wherein a
lens is supported over the heat sink, and wherein the lens
comprises one or more transparent, nonfocusing
regions..Iaddend.
.Iadd.25. The intermediate product of claim 24, wherein the at
least one position marking comprises: a first position marking
having a corner shape, the corner shape of the first position
marking aligned with a desired position for two sides of the
photovoltaic cell assembly; and a second position marking having a
cross shape, the cross shape of the second position marking
underlying the mounting position for the photovoltaic cell
assembly..Iaddend.
.Iadd.26. The intermediate product of claim 24, wherein the heat
sink is affixed to the base plate by glue, a weld, or
screws..Iaddend.
.Iadd.27. The intermediate product of claim 24, wherein the one or
more transparent, nonfocusing regions are aligned with the at least
one position marking of the heat sink..Iaddend.
.Iadd.28. The intermediate product of claim 24, wherein the lens is
configured to focus all incoming light in a region corresponding to
desired placement of a photovoltaic cell assembly on the heat
sink..Iaddend.
.Iadd.29. The intermediate product of claim 24, wherein the lens is
configured to vertically focus rays going through a center of the
lens..Iaddend.
Description
.Iadd.Notice: This is a reissue application of U.S. Pat. No.
9,748,420 B2, issued Aug. 29, 2017, to Krause et al. for HIGH
ACCURACY MODULE ASSEMBLY PROCESS..Iaddend.
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a national phase entry under 35 U.S.C.
.sctn.371 of International Patent Application PCT/EP2014/056091,
filed Mar. 26, 2014, designating the United States of America and
published in English as International Patent Publication WO
2014/154768 A1 on Oct. 2, 2014, which claims the benefit under
Article 8 of the Patent Cooperation Treaty and under 35 U.S.C.
.sctn.119(e) to French Patent Application Serial No. 1352870, filed
Mar. 29, 2013, the disclosure of each of which is hereby
incorporated herein in its entirety by this reference.
TECHNICAL FIELD
This disclosure generally relates to the field of photovoltaic
electricity generators. In particular, it relates to an assembling
method for a base plate of a concentrated photovoltaic module.
BACKGROUND
In recent years, due to the increase of costs associated with
producing electricity from fossil fuels, renewable energy
technology has gained interest. In particular, among the plurality
of renewable energy technologies, Concentrated Photovoltaic (CPV)
technology has been the subject of much research. The advantage of
CPV over the non-concentrated photovoltaic technology results from
the fact that CPV can produce the same amount of electricity of a
much larger non-concentrated photovoltaic cell by focusing the
sunlight via a lens on a smaller active semiconductor area. In
particular, Fresnel lenses are used for CPV technology. As a result
of this approach, it is possible to reduce the costs associated
with the manufacturing of the photovoltaic cell since the materials
used are reduced.
However, by concentrating the sunlight in such a manner, CPV
systems have a tendency to increase their temperature during
operation. This negatively affects the efficiency of the
photovoltaic conversion. Accordingly, it is often necessary to
position CPV cells on top of structures capable of removing
excessive heat from the cells, such as passive or active heat
sinks.
The CPV cell is, therefore, usually assembled on top of a heat
sink, which is thereafter assembled on top of a base plate of a
solar module. The module is then further completed by the lenses
concentrating sunlight on the CPV cells. Such arrangement requires
a plurality of steps at the assembly manufacturing plant, which may
introduce a misalignment between the lens and the CPV cell,
resulting in poor efficiency of the module.
In particular, as schematically illustrated in FIG. 4, a
photovoltaic module 4000 comprises a base plate 4100, on top of
which a plurality of heat sinks 4201 and 4202 are mounted. Each of
the heat sinks has a CPV cell 4301, 4302 mounted thereon. The
photovoltaic module 4000 further comprises a module structure, here
schematically represented by a pillar 4400, which sustains lenses
layer 4500, comprising lenses 4510 and 4520. Accordingly, when
exposed to sunlight, the light is concentrated by lenses 4510 and
4520 on CPV cells 4301 and 4302, respectively. The CPV cells 4301
and 4302 transform sunlight into electricity, but also heat up
while being illuminated, since they do not have an ideal 100%
efficiency. The excess heat is removed by means of heat sinks 4201
and 4202, respectively.
FIG. 4A schematically illustrates a top view of photovoltaic module
4000. In particular, in FIG. 4A, four CPV cells are illustrated.
However, for clarity of representation, the top two are illustrated
with the lenses 4510 and 4521 in place, while lenses 4510 and 4520
for the bottom two CPV cells have been represented only by dashed
lines. In a non-limitative way, lenses 4510 and 4520 are
represented schematically in a rectangular shape, but can have any
other suitable shape, and can be, for instance, square-shaped
Fresnel lenses commonly used for CPV.
FIGS. 4 and 4A illustrate the ideal placement of CPV cells with
respect to the corresponding lens, for achieving maximum efficiency
of the photovoltaic module 4000. However, such ideal placement is
hindered in practice by the assembling process, illustrated in FIG.
5.
As can be seen in FIG. 5, the assembling process usually starts
with (i) the placement of CPV cells 4301, 4302, on top of
respective heat sinks 4201, 4202, in a step S50. This is subjected
to a first misalignment error, which could be, for instance, in the
range of +/-10 .mu.m. The structures so realized are then placed on
the base plate 4100 via a step S51. This is subjected to a second
misalignment error, which could be, for instance, in the range of
+/-10 .mu.m. During a subsequent step S52, the addition of a module
structure or pillar 4400 and a lenses layer 4500 result in the
placement of lenses 4510 and 4520 over the CPV cells 4301 and 4302.
This is subjected to a third misalignment error. This process can,
therefore, be subjected to several misalignment errors, occurring
at each of the assembly steps. For instance, FIGS. 6 and 6A
illustrate a photovoltaic module 6000, a case in which the CPV cell
6303 and heat sink 6203 are misaligned, with respect to their
respective ideal positions 4302A and 4202A. In this case, the
misalignment introduced at any of steps S50-S52 results in a final
misalignment between the lens 4520 and the CPV cell 6303, thereby
decreasing the efficiency of module 6000.
The above-mentioned problems are solved by the teaching of this
disclosure.
BRIEF SUMMARY
In particular, this disclosure can relate to an assembling method
for a base plate of a concentrated photovoltaic module comprising
the steps of: assembling a heat sink on the base plate and
assembling a photovoltaic cell assembly on the heat sink after the
heat sink has been assembled on the base plate.
This provides the beneficial advantage that the heat sink can be
assembled with a misalignment error that does not add to the
misalignment error of assembling of the photovoltaic cell assembly
on the heat sink. In particular, since the latter step is carried
out after the heat sink is in place, the position of the heat sink
is not a cause of added misalignment, but only the misalignment of
the photovoltaic cell assembly contributes to the final
misalignment.
In further advantageous embodiments, the base plate assembling
method can further comprise the step of marking the heat sink, once
assembled on the base plate, with position markings indicating a
mounting position of the photovoltaic cell assembly; and wherein
the step of assembling the photovoltaic cell assembly on the heat
sink is carried out by using the position markings for the
alignment of the assembling.
This provides the beneficial effect that the position of the
photovoltaic cell assembly can be precisely controlled with respect
to the markings during its assembling in the concentrated
photovoltaic module, thereby increasing the efficiency of the
module. In particular, since the markings can be done after the
heat sink is put in place, the misalignment error of the heat sink
on the base plate can be corrected by a precise positioning of the
markings.
In further advantageous embodiments, the photovoltaic cell assembly
may comprise a photovoltaic cell.
This provides the beneficial effect that the mounting of the
concentrated photovoltaic module is simplified, since the markings
on the heat sinks can, for instance, be made by laser in order to
result in the focusing region of the lens, which corresponds to the
region in which the photovoltaic cell should be mounted.
In further advantageous embodiments, the photovoltaic cell assembly
may further comprise a semiconductor structure on which the
photovoltaic cell is assembled.
This provides the beneficial effect that additional electrical
structures, such as a bypass diode, can be realized in the
semiconductor structure. Additionally, if the semiconductor
structure is bigger than the photovoltaic cell, this further
facilitates the handling of the photovoltaic cell assembly.
Further, as the photovoltaic cell assembly, comprising a
semiconductor structure, could contain all necessary electrical
connections, also for the interconnection of neighboring cells, the
assembly on the heat sink only requires a good thermal contact, and
not, as habitually used, a combined good thermal and electrical
contact.
In further advantageous embodiments, the method can further
comprise the step of assembling the photovoltaic cell on the
semiconductor structure with a semiconductor manufacturing
process.
This provides the beneficial effect that precise alignment of the
photovoltaic cell on the semiconductor structure can be
achieved.
In further advantageous embodiments, the step of marking the heat
sink can comprise marking the heat sink with position markings
based on a position of a lens of the concentrated photovoltaic
module.
In this manner, based on the position of the lens, precise markings
can be achieved, thus increasing the alignment of all the
photovoltaic cell assemblies of the module as a whole, and leading
to a decrease in misalignment due to the positioning of the lens
plate.
In further advantageous embodiments, the position marking can be
obtained by a laser.
In further advantageous embodiments, the position of a lens can be
determined with respect to a common reference point between the
lenses layer and the base plate.
This provides the beneficial advantage that the position
coordinates of the focal points of each lens of the lens plate,
also referred to as "lenses layer," which can be measured and
recorded independently prior to the final assembly, can be used for
the position marking on the heat sinks on the base plate.
In further advantageous embodiments, the assembling of the
photovoltaic cell assembly on the heat sink can be realized by
means of gluing and/or laser welding.
This provides the beneficial effect that a stable positioning of
the photovoltaic cell assembly on the heat sink can be realized,
which also allows a very good heat transfer between the two
elements.
Further, this disclosure can relate to a base plate for a
concentrated photovoltaic module comprising at least one heat sink,
wherein the heat sink is marked with position markings indicating a
mounting position of a photovoltaic cell assembly.
Moreover, this disclosure can relate to a concentrated photovoltaic
module comprising a base plate in accordance with the embodiment
above and at least one of a photovoltaic cell assembly and a
lens.
BRIEF DESCRIPTION OF THE DRAWINGS
The disclosure will be described in more detail hereinafter, by way
of example, using advantageous embodiments and with reference to
the drawings. The described embodiments are only possible
configurations in which the individual features may, however, as
described above, be implemented independently of each other or may
be omitted. Equal elements illustrated in the drawings are provided
with equal reference signs. Parts of the description relating to
equal elements illustrated in the different drawings may be left
out. In the drawings:
FIGS. 1 and 1A schematically illustrate a photovoltaic module and a
base plate in accordance with embodiments of this disclosure;
FIG. 2 schematically illustrates a photovoltaic module and base
plate assembly methods in accordance with embodiments of this
disclosure;
FIGS. 2A-2C schematically illustrate exemplary techniques for
obtaining markings on the heat sink in accordance with embodiments
of this disclosure;
FIG. 2D schematically illustrates a base plate assembly method in
accordance with an embodiment of this disclosure;
FIGS. 3 and 3A schematically illustrate photovoltaic modules in
accordance with embodiments of this disclosure;
FIGS. 4 and 4A schematically illustrate a photovoltaic module;
FIG. 5 schematically illustrates a photovoltaic module and base
plate assembly methods; and
FIGS. 6 and 6A schematically illustrate a photovoltaic module.
DETAILED DESCRIPTION
This disclosure will now be described with reference to specific
embodiments. It will be apparent to the skilled person that
features and alternatives from any of the embodiments can be
combined, independently of each other, with features and
alternatives of any other embodiment.
In particular, FIG. 1 illustrates a cross-sectional view and FIG.
1A depicts a top view of a concentrated photovoltaic (CPV) module
1000 comprising a base plate 1100 in accordance with an embodiment
of this disclosure.
Concentrated photovoltaic module 1000 comprises a base plate 1100,
at least one heat sink 1201 and/or 1202, and a lens layer 4500. The
lens layer 4500 comprises at least one lens 4510 and/or 4520,
concentrating sunlight on top of photovoltaic cell assemblies 2002
comprising photovoltaic cell 1301, 1302 and semiconductor structure
1801, 1802.
The CPV module 1000 is assembled, as described in FIG. 2, with an
assembling method that reduces the potential misalignment between
the photovoltaic cell 1301, 1302 and the lens 4510, 4520,
respectively.
In particular, FIG. 2 schematically represents steps of an
assembling method of a base plate and the corresponding module in
accordance with embodiments of this disclosure. More specifically,
on the left side of FIG. 2, cross-sectional views of the different
components of the CPV module 1000 during the assembling method is
represented. On the right side of FIG. 2, the corresponding top
view is illustrated. As in the case of FIGS. 1A and 6, the lens
4510 is not illustrated in the top view, so as to allow the lower
layers to be seen.
A module is realized comprising a module structure, here
schematically represented by a pillar 4400, a heat sink 1201 on top
of base plate 1100 and a lens 4510.
Concerning the specific assembling of the base plate, a heat sink
1201 can be mounted on the base plate 1100 in several manners, such
as by gluing, welding, or screwing, as long as the assembling of
the heat sink 1201 is such that further movement relative to the
base plate 1100 is prevented. This step is realized prior to the
assembling, on top of the heat sink 1201, of the photovoltaic cell
assembly 2002. This is advantageous, since the photovoltaic cell
assembly 2002 can then be assembled in its ideal position, without
being affected by any potential misalignment of the heat sink
1201.
During an optional marking step S20, after assembling of the heat
sink 1201 on base plate 1100, position markings 2701 and 2702 are
realized in the heat sink 1201. The position markings illustrated
in FIG. 2 comprise a first position marking 2701 having a corner
shape and a second position marking 2702 having a cross shape.
Alternatively, during step S20, the lenses layer 4500 and the
module structure are not yet necessarily present and can be
assembled to the base plate later, as described below with
reference to FIG. 2D.
The second position marking 2702 can be used for the subsequent
alignment of the photovoltaic cell assembly 2002 and/or for the
deposition of a contact paste and/or a glue, in case the
photovoltaic cell assembly 2002 is kept in place on the heat sink
1201 in such a manner. The first position marking 2701 can be used
for the subsequent alignment of the photovoltaic cell assembly
2002, for instance, by having two sides of the photovoltaic cell
assembly 2002 overlapping with the two lines and lining up with the
first marking 2701.
In general, the position and shape of the markings can be realized
in any manner that will allow a manual and/or automatic alignment
of the photovoltaic cell assembly 2002 with respect to the marks.
Exemplary techniques for the realization of the markings 2701
and/or 2702 will be described below with reference to FIGS.
2A-2C.
During step S21, the photovoltaic cell assembly 2002 is assembled
by placing the photovoltaic cell 1301 on semiconductor structure
1801. The assembling step S21 is not necessarily carried out after
the step S20. In particular, while step S20 could be carried out at
the base plate manufacturing plant, the step S21 could be carried
out independently at the photovoltaic cell manufacturing plant. As
described above, as a result of the precision of the instruments
used during semiconductor manufacturing, as opposed to the
instruments used during assembling of the CPV module 1000, the
relative placement of the semiconductor structure 1801 and of
photovoltaic cell 1301 could be achieved in the range of
micrometers or lower, thereby effectively resulting in an ideal
alignment between the semiconductor structure 1801 and of
photovoltaic cell 1301.
In a subsequent step S22, the photovoltaic cell assembly 2002 is
mounted on the module 2001 in some embodiments by using the
markings 2701 and 2702 for the positioning and alignment of the
photovoltaic cell assembly 2002.
In particular, with respect to the exemplary markings 2701 and 2702
illustrated in FIG. 2, marking 2702 is used for pouring of a
contact paste and/or glue 3500, as schematically illustrated in
FIG. 3, used to stably mount photovoltaic cell assembly 2002 on the
heat sink 1201. Additionally, marking 2701 is used by making the
sides of photovoltaic cell assembly 2002 to align with the marking
2701, in order to align the photovoltaic cell assembly 2002.
As for step S20, during step S22, the lenses layer 4500 and the
module structure 4400 can be removed or is not yet necessarily
present and can be assembled later, as described below with
reference to FIG. 2D, so as to facilitate the placement of the
photovoltaic cell assembly 2002. In this case, the lenses layer
4500 and the module structure 4400 are designed in such a manner
that the lenses layer 4500 can be subsequently placed or replaced
on the module structure 4400 without losing its relative placement,
with respect to the heat sink 1201, that was used during the
marking step S21. For instance, the relative placement of the lens
plate, also referred to as lenses layer, to the base plate can be
assured by using the exact position coordinates of the focal points
of each lens on an individual lenses layer, which can be measured
and recorded independently from the latter assembling during an
illumination step. These coordinates can be either used with
respect to the position of the module structure or with respect to
the edges of the lenses layer or another convenient reference
common to the lens and base plate. Each coordinate's .[.values.].
.Iadd.value .Iaddend.of each individual lens plate, registered with
the serial number of the lens plate, assures the assembling to the
respective base plate on which the position markings have been
realized using the respective coordinates values. Therefore, an
easy control via the manufacturing execution system is provided and
assures the perfect alignment of the markings on the heat sink on a
base plate with the focal point of the lenses of the respectively
used lens plate.
Although the base plate 1100 above has been described as being
integrally formed with the module structure 4400, this disclosure
is not limited thereto. Alternatively, or in addition, a module
could comprise an independent module structure 4400, within which
the base plate 1100 is placed during the assembling of the
module.
In particular, as illustrated in FIG. 2D, an embodiment of this
disclosure comprises the realization of a structure 1000D,
comprising the base plate 1100, the heat sink 1201, and the
photovoltaic cell assembly 2002. Even more specifically, FIG. 2D
illustrates an assembling method for the base plate 1100, in which
the heat sink 1201 is placed on top of the base plate 1100, in a
first assembling step, not illustrated. During an optional step
S20D, markings 2701 and 2702 are realized, thereby obtaining marked
structure 2001D. Step S21 corresponds to the same step S21
described with reference to FIG. 2, in which the photovoltaic cell
assembly 2002 is assembled, by placing the photovoltaic cell 1301
on semiconductor structure 1801. As for FIG. 2, step S21 is not
necessarily carried out after step S20D. For instance, while step
S20 could be carried out at the base plate manufacturing plant, the
step S21 could be independently carried out at the photovoltaic
cell manufacturing plant. Finally, during an assembling step S22D,
the photovoltaic cell assembly 2002 is mounted on the structure
2001D, by using the markings 2701 and 2702, if optional step S20D
was carried out, for the positioning and alignment of the
photovoltaic cell assembly 2002.
The procedure illustrated in FIG. 2D, therefore, achieves a
structure 1000D comprising the base plate 1100, the heat sink 1201,
and the photovoltaic cell assembly 2002, wherein the misalignment
error of the heat sink 1201 with respect to the base plate 1100
does not negatively affect the total misalignment of the
photovoltaic cell assembly 2002. The structure 1000D can then
subsequently be integrated into a CPV module 1000 by placing it
into a module structure 4400 (FIG. 1) and adding lenses layer 4500
(FIG. 1).
FIGS. 2A-2C schematically illustrate exemplary techniques for
obtaining the markings 2701-2705 or, more generally, any markings
on the heat sink 1201 defining the relative position of the lens
4510 with respect to the heat sink 1201.
More specifically, on the left side of FIGS. 2A-2C, a top view of
the different components of the CPV module 1000 during the marking
step is represented. On the right side of FIGS. 2A-2C, the
resulting marking is illustrated.
The markings can be realized by any technique that allows the
position of the markings to relate to the position of the lens. In
particular, since the relative position of the lens 4510 and of the
photovoltaic cell 1301 is what affects the efficiency of the CPV
module 1000, the positioning of the heat sink 1201 is less critical
than the relative position of the lens 4510 and of the photovoltaic
cell 1301.
In FIG. 2A, the markings are realized by replacing the lens layer
4500 with a masks layer. The masks layer has a plurality of masks
2910, each one having the same positioning of a lens 4510, 4520.
The masks 2910 have holes corresponding to markings 2701, 2702. In
this manner, the laser light can only go through the holes in the
mask 2910, thereby resulting in markings 2701, 2702 being impressed
on the heat sink 1201.
Alternatively, or in addition, the holes in mask 2910 could be
realized such that the markings represent the desired placement of
the photovoltaic cell assembly 2002 (FIG. 2), or could represent
the corners of photovoltaic cell assembly 2002, or could represent
the position of specific border points of the photovoltaic cell
assembly 2002, such as midpoints of each of the sides or
similar.
Alternatively, or in addition, the laser marking could be carried
out through the lens 4510, as illustrated in FIG. 2B.
In particular, lens 4510 could be realized so as to have one or
more transparent, non-focusing regions 4512, at some predetermined
places, such as the corners, etc. In this manner, a vertically
incident laser light would result in a marking 2703 on the heat
sink 1201 corresponding to the focusing region of lens 4510, with
additional alignment markings 2704 corresponding to the
transparent, non-focusing regions 4512.
Still alternatively, or in addition, without the presence of
regions 4512, the marking 2703 could be sufficient for placing and
aligning the photovoltaic cell assembly 2002 (FIG. 2). In
particular, the lens 4510 could be realized so as to focus all
incoming light in a region 2703 corresponding to the desired
placement of the photovoltaic cell 1301 .[.on.]. (FIG. 1) .Iadd.on
.Iaddend.heat sink 1201. By irradiating the whole lens 4510 with a
perpendicular laser, the resultant marking on heat sink 1201 would
then be obtained without knowing the position of the lens' center,
but could be used in order to center the photovoltaic cell assembly
2002.
Still alternatively, or in addition, the marking through the lens
4510 could be operated by instructing the laser to mark the heat
sink 1201 by measuring the position of the marking with respect to
the placement of the lens. For instance, if the lens is constructed
such as to vertically focus rays going through its center, the
laser could measure the position of the lens, identify the center
of the lens, and then carry out a laser marking process through the
lens center. This would result in the heat sink 1201 being marked
in a spot corresponding to the vertical projection of the lens
center. Such marking could then be used during the mounting of the
photovoltaic cell assembly 2002.
Generally, it will be clear to those skilled in the art that, for
each focusing scheme of a given lens 4510, a laser marking process
can be designed such that the heat sink 1201 will be marked in a
way that impresses, on the heat sink 1201, markings 2701 and/or
2702, providing information on the relative position of the lens
4510 and of the heat sink 1201.
It will also be clear that the lens can be designed in such a
manner that the focusing of the laser wavelength is at a focal
distance corresponding to the top plane of the heat sink 1201,
while the focusing of the sunlight is at a focal distance
corresponding to the top plane of the photovoltaic cell 1301. In
this manner, it is possible to achieve a precise marking 2701,
2702, 2703, 2704, as well as efficiently focus the sunlight on the
photovoltaic cell 1301.
Still alternatively, or in addition, the heat sink could be covered
in a photosensible material, such that other illumination systems,
such as sunlight, can be used to impress markings on the
photosensible material.
Alternatively, or in addition, the markings could be realized in
another manner, such as mechanically. For instance, as illustrated
in FIG. 2C, a lens 4513 having one or more holes 4514 could be put
in place as a final lens or as a processing lens to be then
replaced by lens 4510, and a drill could be passed through the
openings 4514 so as to produce markings 2705 on the heat sink
1201.
Alternatively, or in addition, marking techniques, such as, for
instance, mechanical scribing or stamping techniques, can be
realized.
Alternatively, or in addition, the lenses layer 4500 and the module
structure are not yet necessarily present and can be assembled to
the base plate later, and the marking of the heat sinks can be
realized without the presence of the lenses layer but only by
taking into account the position coordinates of the focal points of
each lens, which could be measured and recorded independently for
each individual lenses layer.
Although the base plate 1100 above has been described as being
integrally formed with the module structure 4400, this disclosure
is not limited thereto. Alternatively, or in addition, a module
could comprise an independent module structure 4400, within which
the base plate 1100 is placed during the assembling of the
module.
Alternatively, or in addition, the markings could be realized on
the heat sink 1201 with respect to the heat sink itself. For
instance, with knowledge, from the design of the module, of the
focusing positions of the lenses on top of the heat sinks assembled
on the base plate, the heat sinks could be marked without using the
lenses in order to provide position information, but with respect
to the ideal position of the lenses.
Alternatively, or in addition, the markings could be realized on
the heat sinks 1201 with respect to the position of the module
structure 4400, which is precisely related to the positioning of
the lenses that are assembled in a highly accurate and controlled
manner on the same module structure.
Accordingly, generally, any marking procedure that will realize a
marking 2701-2705 on the heat sink 1201, which allows the
determination of the position of a predetermined point of lens
4510, once mounted on the module 1000, preferably the focusing
point, with respect to heat sink 1201, can be used.
As a result of this approach, the photovoltaic cell assembly 2002
can be reliably mounted on the heat sink 1201 in a position that is
precisely known, with respect to the position of the lens 4510,
such that efficiency of the CPV module 1000 is increased. In
particular, even if the placement of the heat sink 1201 with
respect to the base plate 1100 is not precise, this does not affect
this disclosure.
FIGS. 3 and 3A schematically illustrate a photovoltaic module 3010
and 3020 in accordance with embodiments of this disclosure. In
particular, while FIG. 3 illustrates the cross-sectional view of
the modules, FIG. 3A illustrates the corresponding top view,
without the lens 4510.
As can be seen in FIGS. 3 and 3A, the solar cell assembly 2002 can
be fixed to the heat sink 1201 via the glue and/or contact paste
3500, which can be deposited on the heat sink 1201 precisely, with
the help of markings 2702 (FIG. 2).
Alternatively, or in addition, the solar cell assembly 2002 can be
fixed to the heat sink 1201 via a laser welding 3601, 3602.
Although in the above-described embodiments the photovoltaic cell
assembly has been illustrated as being mounted on top of heat sink
1201, this disclosure is not limited thereto. Alternatively, or in
addition, one or more of the photovoltaic cell assemblies of the
photovoltaic module could be mounted directly on the base plate
1100. In this case, the base plate 1100 would act as heat sink 1201
and as a structural element of the photovoltaic module at the same
time. Accordingly, in this case, the markings 2701 and 2702 would
be realized on the base plate 1100.
Additionally, although in the above-described embodiments the
photovoltaic cell assembly has been illustrated as comprising a
plurality of heat sinks 1201, 1202, this disclosure is not limited
thereto. Alternatively, only a single, possibly continuous, heat
sink could be used on top of base plate 1100 as a mounting point
for one or more of the photovoltaic cell assemblies 2002.
Furthermore, although in the above-described embodiments, the
photovoltaic cell assembly 2002 has been illustrated as comprising
both a photovoltaic cell 1301 and a semiconductor structure 1801,
this disclosure is not limited thereto. Alternatively, or in
addition, one or more of the photovoltaic cell assemblies of the
photovoltaic module could comprise only the photovoltaic cell 1301
mounted directly on top of the heat sink 1201.
Moreover, although alternative approaches have been described with
respect to one or more specific embodiments, it will be clear to
those skilled in the art, that those alternative approaches can be
applied to all other above-described embodiments, independently or
in combination with each other.
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