Solar Cell Unit With Secondary Optical Element
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Solution Overview
Problem
Conventional solar cell receivers have a significant cost component due to the large size of the carrier, which hinders cost-effective production and efficient heat removal during high-temperature solar irradiation.
Innovation Solution
A solar cell unit design featuring a semiconductor body with one-sided terminal contacts and a secondary optical element connected via a polymer adhesive layer, allowing for reduced carrier size and enhanced thermal coupling, along with metallic connecting elements for electrical connections, which promotes efficient heat removal and cost savings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the carrier size is reduced to lower costs, then manufacturing cost decreases, but heat removal capability deteriorates
Solution Approach 1:
The terminal contacts are segmented into two distinct locations: front-side contacts for electrical connection and a separate rear-side contact area for thermal management. This segmentation allows the carrier to be minimized in size while maintaining both electrical functionality and heat removal capability through dedicated contact zones.
Solution Approach 2:
The patent introduces an intermediate structural arrangement where the rear-side contact serves as a mediator between the semiconductor body and the carrier, providing thermal coupling without requiring a large carrier area. This intermediary contact area enables heat transfer while allowing the overall carrier dimensions to be reduced.
2Reliability
If terminal contacts are arranged on opposite sides of the carrier, then electrical connectivity is improved, but carrier size increases
Solution Approach 1:
The patent transitions from a two-dimensional planar arrangement of contacts to a three-dimensional spatial configuration by placing contacts on opposite faces (front and rear) of the semiconductor body. This dimensional change allows electrical connectivity to be achieved without expanding the carrier's planar footprint, as contacts are distributed across different spatial planes rather than requiring increased lateral separation.
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
The design reduces carrier size by 15% to 30%, enhances heat removal, and maintains ease of wiring, thereby achieving a cost-effective and resource-saving manufacturing option while preventing short circuits through strategic contact placement and conductive bridges.
Implementation Method 1
The light is conducted from the secondary optical element along the optical axis to the polymer adhesive layer, so as to penetrate the polymer adhesive layer and to fall on the front side of the semiconductor body
Implementation Method 2
The secondary optical element has a bottom side, whereby the secondary optical element guides light to the front side of the semiconductor body
Implementation Method 3
at least parts of the bottom side of the secondary optical element are non-positively connected to the front side of the semiconductor body and/or to the top side of the carrier solely by a polymer adhesive layer
Implementation Method 4
The semiconductor body has a first and a second terminal contact for electrical contacting... An advantage of the full-surface back-side contacting is that there is good thermal coupling with the carrier to prevent overheating of the solar cell
Data Source
AI summary
A solar cell unit having a semiconductor body formed as a solar cell and having a front side and a back side, a carrier with a top side enclosed by at least four edges, a bottom side, and a first contact surface, formed on the top side and connected to the first terminal contact, and a second contact surface, connected to the second terminal contact and spaced apart from the first contact surface, and a secondary optical element. A back side of the semiconductor body is non-positively connected to a part of the top side of the carrier. The secondary optical element guides light to the front side of the semiconductor body and at least parts of the bottom side of the secondary optical element are non-positively connected to the front side of the semiconductor body and/or to the top side of the carrier by a polymer adhesive layer.