Off-Axis Solar Concentrator Layout for Cooling and Optical Alignment
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Solution Overview
Problem
Existing solar concentrators face challenges in aligning optical elements with photovoltaic cells precisely while providing adequate thermal and environmental protection, often requiring costly manufacturing steps or sacrificing efficiency to reduce costs.
Innovation Solution
A solar concentrator design featuring a housing with a receiving wall, reflecting wall, and end walls that allows for off-axis configuration of photovoltaic cells and optical elements, using clips and tabs for precise alignment and a window for enclosure, which simplifies the alignment process and provides protection from the environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If solar cells are placed in the back of an enclosure to provide environmental protection, then the solar cells are protected from the environment, but it becomes difficult to remove excess heat, requiring a larger heat sink
Solution Approach 1:
The patent transitions from a conventional on-axis configuration to an off-axis configuration, changing the spatial arrangement dimension. The optical axis is angled relative to the enclosure axis, allowing heat sinks to be positioned at the sides rather than directly behind the solar cells, thus providing heat removal pathways without compromising environmental protection.
Solution Approach 2:
The patent introduces asymmetric positioning of components. The solar cells are positioned off-center relative to the enclosure, with the optical axis at an angle to the enclosure axis. This asymmetric arrangement creates space for heat sinks on the sides while maintaining environmental protection through the enclosed structure.
2Manufacturing precision
If costly manufacturing steps are used to achieve precise alignment of optical elements with solar cells, then alignment precision is improved, but manufacturing costs increase
Solution Approach 1:
The patent incorporates alignment features directly into the molding process. Alignment pins, slots, and registration features are integrated into the housing and component molds, establishing precise geometric relationships during manufacturing rather than requiring post-assembly adjustment. This preliminary action ensures alignment precision while avoiding costly manual alignment steps.
Solution Approach 2:
The patent replaces complex mechanical adjustment mechanisms with molded-in geometric constraints. Instead of using adjustable mounts, screws, or mechanical alignment systems that require precise mechanical tolerances and manual adjustment, the design uses molded features such as pins fitting into slots, angled surfaces, and integrated mounting structures that provide alignment through the molding process itself.
3Ease of manufacture
If conventional on-axis configuration is used, then manufacturing is simpler, but thermal management becomes more difficult and efficiency is reduced
Solution Approach 1:
The patent changes the spatial configuration from on-axis to off-axis, allowing the optical elements and solar cells to be positioned at an angle relative to the enclosure. This dimensional change enables side-mounted heat sinks and improves thermal management while maintaining manufacturing simplicity through integrated molding of the off-axis configuration.
Solution Approach 2:
The patent applies different functional requirements to different parts of the system. The optical path is optimized for light concentration efficiency with precise angular positioning, while the enclosure structure is optimized for thermal management with side-mounted heat sinks. Each component is designed with local quality optimized for its specific function rather than compromising overall design for uniform simplicity.
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
Enables quick and precise alignment of optical elements with photovoltaic cells in an off-axis configuration, enhancing efficiency while maintaining thermal and environmental protection, thus reducing manufacturing costs and improving energy production.
Implementation Method 1
Solar concentrators may be configured in various ways and typically include refracting optics, reflecting optics or various combinations thereof
Implementation Method 2
Solar concentrators may be configured in various ways and typically include refracting optics, reflecting optics or various combinations thereof
Implementation Method 3
Photovoltaic solar concentrators typically are used to generate electrical power by concentrating sunlight onto photovoltaic devices
Implementation Method 4
excess heat must be removed and the solar cells must be protected from the environment
Data Source
AI summary
A solar concentrator including a housing having a receiving wall, a reflecting wall and at least two end walls, the receiving, reflecting and end walls defining a three-dimensional volume having an inlet, wherein a vertical axis of the housing is generally perpendicular to the inlet, a receiver mounted on the receiving wall of the housing, the receiver including at least one photovoltaic cell, wherein a vertical axis of the receiver is disposed at a non-zero angle relative to the vertical axis of the housing, at least one clip disposed on the reflecting wall, an optical element received within the three-dimensional volume, the optical element including at least one tab, the tab being engaged by the clip to align the optical element with the receiver, and a window received over the inlet to enclose the housing.