Solar cell structure including a plurality of concentrator elements with a notch design and predetermined radii and method

Abstract

A solar cell concentrator structure includes a first concentrator element having a first aperture region and a first exit region including a first back surface region and a first corner region. The structure also includes a second concentrator element integrally formed with the first concentrator element. The second concentrator element includes a second aperture region and a second exit region-including a second back surface region and a second corner region. Additionally, the structure includes a first radius of curvature of 0.10 mm and less characterizing the first corner structure and the second corner structure, a first coupling region between the first exit region and a first surface region of a first photovoltaic device. The structure further includes a second radius of curvature of 0.10 mm and less characterizing a region between the first concentrator element and the second concentrator element.

1 . A solar module comprising:
 a solar cell concentrator structure comprising:
 a thickness of glass material ranging from 5 mm to 7 mm, the thickness of glass material comprising a plurality of integrally formed concentrator elements including a first concentrator element configured in a first shape having a first curved wall region, the first concentrator element including a first aperture region and a first exit region, the first exit region including a first back surface region; 
 and a second concentrator element configured in a second shape having a second curved wall region and the second concentrator element being integrally formed with the first concentrator element, the second concentrator element including a second aperture region and a second exit region, the second exit region including a second back surface region; 
 a separation region provided between the first concentrator element and the second concentrator element, the separation region being characterized by a width separating the first exit region from the second exit region; 
 a second radius of curvature characterizing a region between the first concentrator element and the second concentrator element, the second radius of curvature being less than about 0.10 mm and greater than 0.001 mm; 
 a geometric concentration range from about 1.8 to 4.5 characterizing the first concentrator element and the second concentrator element; 
 a triangular shaped region including an apex defined by the second radius of curvature and a base defined by the separation region; and 
 a refractive index of about 1 characterizing the triangular region; 
   a plurality of photovoltaic devices comprising a first photovoltaic device comprising a first surface region coupled to the first exit region and a second photovoltaic device comprising a second surface region coupled to the second exit region.   
     
     
         2 . The solar module of  claim 1  wherein the second exit region includes a second corner region and the first exit region includes a first corner region and further comprising a first radius of curvature characterizing the first corner structure, the first radius of curvature being less than 0.10 mm and greater than 0.001 mm. 
     
     
         3 . The solar module of  claim 1  wherein the first concentrator element integrally formed with the second concentrator element are essentially a single piece of the glass material. 
     
     
         4 . The solar module of  claim 1  wherein the first concentrator element integrally formed with the second concentrator element is molded. 
     
     
         5 . The solar module of  claim 1  wherein the first concentrator element and the second concentrator element are characterized by a refractive index of about 1.4 and greater. 
     
     
         6 . The solar module of  claim 1  wherein the first concentrator is characterized by a first truncated pyramid shape and the second concentrator is characterized by a second truncated pyramid shape. 
     
     
         7 . The solar module of  claim 1  wherein the coupling region comprises an optical coupling material. 
     
     
         8 . The solar module of  claim 1  wherein the optical coupling material comprises an optical grade epoxy, or ethylene vinyl acetate (EVA), or silicones, or polyurethanes. 
     
     
         9 . The solar module of  claim 1  wherein the first concentrator element is optically coupled to a first photovoltaic region and the second concentrator element is optically coupled to a second photovoltaic region. 
     
     
         10 . The solar module of  claim 1  wherein the second radius of curvature is greater than an amount that causes a crack within a portion of a thickness of the glass material. 
     
     
         11 . A solar module apparatus comprising a cell concentrator structure, the solar cell concentrator structure comprising:
 a piece of optical material made of glass characterized by a first spatial direction and a second spatial direction, the first spatial direction being normal to the second spatial direction;   a first concentrator element and a second concentrator element provided within a first portion of the piece of optical material and a second portion of the piece of optical material, respectively, defined along the second spatial direction, the first concentrator element and the second concentrator element having a thickness of 5 mm to 7 mm;   an aperture region provided on a first surface region of the piece of optical material, the aperture region being adapted to allow electromagnetic radiation to be illuminated thereon;   an exit region provided on a second surface region of the piece of optical material;   a separation region provided between the first concentrator element and the second concentrator element, the separation region being characterized by a width;   a second radius of curvature of 0.10 mm and less within a predetermined depth of the piece of optical material, the second radius of curvature being provided between the first concentrator element and the second concentrator element.   
     
     
         12 . The solar module apparatus of  claim 11  wherein the piece of optical material is essentially the glass material; wherein the first concentrator element characterized by a first radius of curvature. 
     
     
         13 . The solar module apparatus of  claim 11  wherein the second radius of curvature reduces an efficiency of the first concentrator element and the second concentrator element by about 50% and less. 
     
     
         14 . The solar module apparatus of  claim 11  wherein the piece of optical material is characterized by a refractive index of about 1.4 and more. 
     
     
         15 . The solar module apparatus of  claim 11  wherein the second radius of curvature is an apex of a triangular region having a base provided within a portion of a first exit region of the first concentrator element and a second exit region of the second concentrator element. 
     
     
         16 . The solar module apparatus of  claim 11  wherein the second radius of curvature is an apex of a triangular region having a base provided within a portion of a first exit region of the first concentrator element and a second exit region of the second concentrator element, the triangular region having a refractive index of about 1.0. 
     
     
         17 . A solar module comprising a solar cell concentrator structure, the solar cell concentrator structure comprising:
 a plurality of concentrator elements integrally formed with each other, the plurality of concentrator elements including a first concentrator element, the first concentrator element including a first aperture region and a first exit region, the first exit region including a first back surface region, the first concentrator element being characterized by a refractive index of about 1.4 and greater, and a second concentrator element integrally formed with the first concentrator element, the second concentrator element being characterized by a refractive index of about 1.4 and greater, the second concentrator element including a second aperture region and a second exit region, the second exit region including a second back surface region, the first concentrator element integrally formed with the second concentrator element being essentially a single piece of molded glass material, the first concentrator element being optically coupled to a first photovoltaic region and the second concentrator element being optically coupled to a second photovoltaic region;   a thickness of 5 mm to 7 mm characterizing the first concentrator element and the second concentrator element;   a first coupling region between the first exit region and a first surface region of a first photovoltaic device, the first coupling region including an optical coupling material comprising an EVA material;   a second coupling region between the second exit region and a second surface region of a second photovoltaic device;   a separation region provided between the first concentrator element and the second concentrator element, the separation region being characterized by a width separating the first exit region from the second exit region;   a radius of curvature characterizing a region between the first concentrator element and the second concentrator element, the radius of curvature being about between 0.001 mm and 0.10 mm;   a triangular shaped region including an apex defined by the radius of curvature and a base defined by the separation region;   a refractive index of about 1 characterizing the triangular region; and   a plurality of photovoltaic devices including the first photovoltaic device and the second photovoltaic device.