Microsystem enabled photovoltaic modules and systems
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Solution Overview
Problem
Photovoltaic systems are not competitive with fossil fuel-generated electricity due to high costs, necessitating a reduction in photovoltaic module and assembly costs while improving efficiency.
Innovation Solution
The use of thin, small-area photovoltaic solar cells batch-fabricated and assembled onto low-cost stainless steel or polymer substrates with fluidic self-assembly technology, combined with a moveable lens assembly for sunlight concentration and micro-optical elements for precise solar tracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional photovoltaic modules are used, then electricity generation is achieved, but system cost is high and not competitive with fossil fuel electricity
Solution Approach 1:
The system segments the photovoltaic module into separate functional components: a low-cost substrate structure and independently mounted PV cells. This allows optimization of each component separately and reduces overall system cost while maintaining electricity generation capability.
Solution Approach 2:
The patent introduces an intermediary optical system (lenses or reflectors) between the sunlight source and the PV cells. This intermediary concentrates solar energy onto smaller, more efficient PV cells, reducing the total PV cell area needed and lowering system cost while maintaining generation capability.
2Device complexity
If photovoltaic module area is reduced to lower cost, then system cost decreases, but sunlight capture efficiency is reduced
Solution Approach 1:
The patent changes the optical parameters of the system by introducing concentration optics (lenses or reflectors) that alter the path and density of sunlight. This allows a smaller PV cell area to capture the same amount of solar energy that would otherwise require a larger area, thus reducing cost while maintaining efficiency.
Solution Approach 2:
The system uses a composite structure combining optical elements (lenses or reflectors) with PV cells on a substrate. This composite design enables enhanced light capture and concentration, allowing reduced PV cell area while maintaining or improving sunlight capture efficiency.
3Device complexity
If PV cell area is reduced, then material cost and assembly cost decrease, but thermal management becomes more challenging
Solution Approach 1:
The patent extracts the thermal management function as a separate, dedicated component rather than relying on the PV cell mounting structure alone. This allows specialized thermal solutions (heat sinks, thermal vias, or active cooling) to be implemented specifically for the concentrated heat load, effectively managing temperature despite reduced cell area.
Solution Approach 2:
The system implements preliminary thermal management measures by designing the substrate and mounting structure with integrated thermal conduction paths before the PV cells are subjected to concentrated solar loading. This preemptive thermal design prevents overheating even with high power density on small cells.
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 approach reduces costs and increases efficiency by concentrating sunlight onto small-area photovoltaic cells, allowing for effective solar energy generation with reduced material usage and improved thermal management.
Implementation Method 1
The Keplerian telescope elements are designed and arranged to substantially couple radiation that is incident on their objective surfaces, within the predetermined absorption wavelength band, and within the predetermined field of view into the corresponding pupil element
Implementation Method 2
Each pupil element is designed and arranged to substantially relay radiation that is coupled into it from the corresponding Keplerian telescope element and within the predetermined absorption wavelength band into the corresponding PV element
Implementation Method 3
The absorber layer includes an array of PV elements. Each PV element has a top surface and a predetermined absorption wavelength band
Data Source
AI summary
A photovoltaic (PV) module includes an absorber layer coupled to an optic layer. The absorber layer includes an array of PV elements. The optic layer includes a close-packed array of Keplerian telescope elements, each corresponding to one of an array of pupil elements. The Keplerian telescope substantially couple radiation that is incident on their objective surfaces into the corresponding pupil elements. Each pupil element relays radiation that is coupled into it from the corresponding Keplerian telescope element into the corresponding PV element.