Direct Bonded CPV Solar Cell Assembly Heat Dissipation
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Solution Overview
Problem
Concentrator Photovoltaic (CPV) systems face efficiency losses due to heat buildup and require separate manufacturing steps for photovoltaic cells and diodes, leading to increased costs and manufacturing complexity, while existing bonding materials introduce electrical and thermal resistance.
Innovation Solution
A solar cell assembly structure with a semiconductor structure that directly bonds the photovoltaic cell and diode, using molecular or direct bonding, and an electrically conductive substrate to improve heat dissipation and reduce manufacturing steps, allowing for a single heat sink to be used across multiple assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional bonding materials are used to connect photovoltaic cells and diodes, then assembly is simplified, but electrical and thermal resistance increases
Solution Approach 1:
The patent removes intermediate bonding materials from the connection path between photovoltaic cells and diodes. By directly bonding semiconductor layers without adhesive layers, it eliminates the electrical and thermal resistance introduced by conventional bonding materials while maintaining assembly simplicity through direct semiconductor-to-semiconductor bonding.
Solution Approach 2:
The patent creates an asymmetric structure where the photovoltaic cell and diode are integrated at different vertical levels on the heat sink. The diode is positioned at a first level while the photovoltaic cell is at a second level, allowing direct electrical and thermal connection without requiring symmetric bonding interfaces, thus eliminating the need for resistive bonding materials.
2Manufacturing precision
If separate manufacturing steps are used for photovoltaic cells and diodes, then each component can be optimized independently, but manufacturing complexity and costs increase
Solution Approach 1:
The patent merges the manufacturing processes for photovoltaic cells and diodes into a single integrated structure. Both components are formed simultaneously on the same heat sink substrate using the same semiconductor layers and bonding processes, eliminating the need for separate manufacturing steps while maintaining the ability to optimize each component's electrical and thermal properties independently through selective doping and layer configuration.
3Temperature
If multiple separate heat sinks are used for each assembly, then heat dissipation is optimized for each unit, but manufacturing costs and complexity increase
Solution Approach 1:
The patent creates a universal heat sink structure that can accommodate multiple photovoltaic cell-diode assemblies simultaneously. The single heat sink serves multiple functions: it provides thermal management for all cells, acts as a common electrical interconnection substrate, and enables series or parallel configuration of multiple cells. This multi-functional approach maintains optimal heat dissipation while eliminating the need for multiple separate heat sinks.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enhances electrical conduction, improves heat transfer, reduces manufacturing complexity, and lowers costs by eliminating the need for separate diodes and cells, while enabling efficient heat dissipation and easier handling of thin multi-junction solar cells.
Implementation Method 1
molecular or direct bonding
Implementation Method 2
molecular or direct bonding
Implementation Method 3
electrically and thermally conductive glue, solder paste or adhesive layer
Implementation Method 4
Con concentrator photovoltaic (CPV) technology has been the subject of much research
Data Source
AI summary
This disclosure relates to a solar cell assembly structure for supporting a concentrator photovoltaic cell comprising a semiconducting structure and a diode, wherein the semiconducting structure comprises a first semiconducting region at least a part of which for placing the concentrator photovoltaic cell structure, and a second semiconducting region for realizing the diode within or on the second semiconducting region and wherein the part of the first semiconducting region for placing the concentrator photovoltaic cell structure and the second semiconducting region are not vertically overlapping.