Solar Concentrator Optics Assembly With Cooling and Precise Alignment
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Solution Overview
Problem
Existing solar radiation conversion systems face issues such as limited accessibility of individual units, temperature-dependent efficiency variability, fragility of primary optics, alignment challenges, and humidity penetration, leading to reduced efficiency and durability.
Innovation Solution
A system comprising a primary optics aligned and secured by a spacer and alignment member, with a secondary optics for uniform light distribution, and a hydraulic cooling system, ensuring precise alignment, hermetic sealing, and thermal management to enhance efficiency and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional silicon photovoltaic cells are used, then the system is simpler and cheaper, but the conversion efficiency is limited to about 14%
Solution Approach 1:
The patent divides the optical system into multiple functional components: primary optics for light collection, secondary optics for light distribution, and multi-junction cells for high-efficiency conversion. This segmentation allows each component to be optimized independently, achieving 38-40% efficiency while managing complexity through modular design
Solution Approach 2:
The patent implements a nested optical system where secondary optics are positioned within the focal region of primary optics. The multi-junction cells are nested within the secondary optics structure, creating a compact hierarchical arrangement that maximizes space utilization and light conversion efficiency
2Ease of manufacture
If primary optics are made of thin plastic material, then the device is lighter and easier to manufacture, but it becomes fragile and susceptible to UV degradation and thermal deformation
Solution Approach 1:
The patent employs composite construction for primary optics, combining plastic optical material with protective glass layers and structural support frameworks. This composite approach maintains the manufacturing advantages of plastic while adding the durability, UV resistance, and thermal stability of glass and metal components
Solution Approach 2:
The patent incorporates protective measures before degradation occurs: UV-resistant coatings are applied to plastic optics during manufacturing, thermal expansion compensation structures are pre-designed into the mounting system, and protective glass layers are laminated onto the optical surfaces to prevent physical damage and chemical degradation
3Productivity
If photovoltaic cells are directly exposed to concentrated solar radiation, then the system is simpler, but the cells overheat and efficiency decreases due to temperature sensitivity
Solution Approach 1:
The patent introduces secondary optics as an intermediary component between primary optics and photovoltaic cells. This intermediary distributes the concentrated light uniformly across the cell surface, preventing localized overheating while maintaining high overall illumination levels for efficient conversion
Solution Approach 2:
The patent uses optical copying principles where secondary optics create multiple virtual light sources that redistribute the concentrated energy. This optical copying effect spreads the thermal load across the entire cell surface rather than concentrating it at a single focal point, maintaining efficiency while managing temperature
4Productivity
If elementary units are assembled into modules without individual accessibility, then the module structure is more compact, but maintenance and replacement require replacing the entire module
Solution Approach 1:
The patent designs modules with segmented, modular elementary units that are mechanically coupled but electrically and optically functional. Each unit can be independently accessed, removed, and replaced through the module structure, allowing maintenance of individual components without replacing the entire assembly while maintaining compact integration
5Ease of manufacture
If alignment between primary optics and photovoltaic cells is not precisely maintained, then the system is more tolerant to manufacturing variations, but light concentration efficiency is lost
Solution Approach 1:
The patent implements preliminary alignment features during manufacturing: precision-machined mounting surfaces with built-in alignment references, pre-positioned adjustment mechanisms, and self-centering optical mounts. These preliminary actions ensure that components are pre-aligned to within tight tolerances before final assembly, maintaining efficiency while accommodating normal manufacturing variations
Solution Approach 2:
The patent incorporates adjustable parameters in the mounting system that allow fine-tuning of alignment after assembly. Mechanical adjustment mechanisms enable modification of optical axis positioning and focal distance, allowing the system to compensate for manufacturing tolerances and maintain optimal efficiency through parameter optimization
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 system achieves high efficiency and extended lifespan by ensuring precise alignment, protecting components from environmental factors, and allowing for easy maintenance, while maximizing light conversion and heat recovery for various applications.
Implementation Method 1
a primary optics (for example a lens) collecting the solar energy and converging it onto a high-efficiency photovoltaic cell
Implementation Method 2
the solar radiation incident onto the photovoltaic cells is transformed into electric current
Implementation Method 3
a secondary optics which, in turn, contributes to distribute the solar radiation onto the photovoltaic cell
Implementation Method 4
A thermal dissipation system further contributes to convey the heat generating into the cell onto a cooling (for example hydraulic) circuit
Implementation Method 5
the heated fluid can be used for different purposes, for example heating for civil use
Data Source
AI summary
A system or device for concentrating the light radiation of the type to be used for converting the solar radiation into electric current and/or thermal energy is disclosed. The device mainly having a primary optics apt to be exposed to the solar radiation and to allow the passage thereof therethrough, the primary optics being positioned on a hollow spacer member, which is perfectly aligned and at the same time locked, by means of a joint member.