Low-cost efficient solar panels
09780722 · 2017-10-03
Inventors
Cpc classification
F24S23/74
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F24S2020/16
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H01L31/054
ELECTRICITY
Y02E10/47
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
H02S40/425
ELECTRICITY
H01L31/0232
ELECTRICITY
F24S50/20
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H01L31/0547
ELECTRICITY
F24S23/79
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H01L31/02322
ELECTRICITY
Y02E10/52
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
F24S30/425
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
H02S40/00
ELECTRICITY
International classification
H01L31/00
ELECTRICITY
H02S40/00
ELECTRICITY
Abstract
A solar panel that attains very low cost/Watt objectives is achieved by applying an optical concentrator with planar symmetry in combination with a simple 1-axis tracking system. The concentrator uses a Cassegrain optical system to provide moderate concentration factors that can be adjusted by varying the ratio of the focal lengths of the concave and convex reflecting surfaces. Concentrator dimensions can be scaled to any convenient size. They can be arrayed in parallel to form a solar panel that has the same form factor as a 1-sun solar panel. One-axis tracking is achieved by simply rotating the collector elements in synchronism so the sun is maintained in the plane of symmetry for each of the collector elements that comprise the panel.
Claims
1. A solar panel having a base with a fixed location and fixed orientation as installed and a footprint compatible with standard solar panels and comprised of concentrating solar collectors supported by an adjustable mount attached to said base and with said solar collectors arrayed in parallel to each other in a single common plane with each solar collector having: a. a first long concave reflecting surface having width, W1, and an area, A1, when projected onto a plane perpendicular to incoming parallel rays of the sun that concentrates incoming parallel rays of the sun onto a focal line, and b. a second long reflecting surface having width, W2, and an area, A2, when projected onto a plane perpendicular to incoming parallel rays of the sun with W2<W1 and A2<A1 that reflects all of said concentrated rays from said first long concave reflecting surface in a direction parallel to said incoming parallel rays from the sun striking said first concave reflecting surface and directs these concentrated parallel rays directly onto c. a narrow line of photovoltaic cells located within the concave arc of said first reflecting surface or in immediate proximity to said arc at normal incidence when projected onto a plane perpendicular to the length of said long reflecting surface and having a width equal to said width of said second long reflecting surface, W2, in order to intercept all of said concentrated parallel solar rays reflected from said second long reflecting surface, and d. said second long reflecting surface is convex and has a plane of bilateral symmetry that contains its focal line and is parallel to incident rays from the sun, and e. said second long convex reflecting surface has a cross-section in a plane perpendicular to said focal line that is parabolic in shape with a width in said plane of W2, and f. said first long concave reflecting surface has a cross-section in a plane perpendicular to said focal line that is parabolic in shape, and g. said first long concave reflecting surface has a plane of bilateral symmetry coincident with said plane of bilateral symmetry of said second long reflecting surface and a focal line coincident with said focal line of said second long reflecting surface, and h. said second long reflecting surface directs incoming rays from the sun that are parallel to said common plane of symmetry into a beam of rays parallel to said plane of symmetry and parallel to said incoming rays from the sun and directs this beam directly onto said narrow line of photovoltaic cells at normal incidence when projected on a plane perpendicular to the length of said second long reflecting surface, and i. said second convex reflecting surface has a focal length, L2, that is smaller than the focal length, L1, of said first concave surface and the focal length ratio L2/L1 is equal to W2/W1 and A2/A1, and j. said narrow line of photovoltaic cells extends for an equal distance either side of said plane of symmetry and has a width, WP, that is equal to said width of said second reflecting surface measured in a plane perpendicular to the length of said second long reflecting surface, WP=W2, and k. said narrow line of photovoltaic cells having width, WP, equal to W2 is located within the concave arc of said first reflecting surface or in immediate proximity to said arc centered on the line of intersection of said first long concave reflecting surface with said plane of symmetry, and l. reflected rays from said second reflecting surface are incident directly on said narrow line of photovoltaic cells at normal incidence when projected on a plane perpendicular to said focal line, and m. said solar collector has an axis of rotation that is parallel to said coincident focal lines and lies in said plane of bilateral symmetry, and n. said solar collector has a height-to-width ratio of 1:4 where the height is equal to said focal length of said first reflecting surface, L1, and the width is equal to said width of said first reflecting surface, W1, (L1/W1=1/4), and whereby, the area of said narrow line of photovoltaic cells, A2, is reduced in the ratio of said width of said second reflecting surface to said width of said first reflecting surface, W2/W1=A2/A1=L2/L1, while generating electrical power equal to (1−W2/W1) times that generated by photovoltaic cells without the benefit of concentration having a cross-sectional area when projected onto a plane perpendicular to incoming parallel rays of the sun equal to said area of said first reflecting surface, A1, and the area and cost of said photovoltaic cells is reduced by said ratio, W2/W1, and whereby said solar collector height-to-width ratio of 1:4 minimizes solar collector construction materials and enables minimum spacing of said solar collectors while achieving compatibility with 180-degree rotation of said solar collectors, as arrayed in parallel on said mount which mount can be adjusted to intercept an optimal flux of solar radiation by minimizing the angle between the normal to said common plane of said solar collectors and the incident solar rays.
2. The solar panel of claim 1 wherein said concentrating solar collectors are modified such that: a. said second convex reflecting surface has a cross-section that is distorted slightly from a parabolic shape by reducing the distance between the original focus and the convex reflecting surface at its intersection with said bisecting plane to produce reflected rays from said second convex reflecting surface having an acute angle of convergence towards said plane of bilateral symmetry equal to arctan [2*(L2/L1).sup.2/(1−L2/L1)] relative to the incoming parallel rays from the sun in the x-y plane perpendicular to said focal line, and whereby the light intensity across said width of said narrow line of photovoltaic cells is evened out by compensating for the obscuration caused by said second convex reflecting surface which otherwise would cause a partial shadow near the center line of said narrow line of photovoltaic cells.
3. The solar panel of claim 1 wherein said concentrating solar collectors are modified such that: a. said focal length, L2, and the position of said focal line of said second convex reflecting surface relative to said focal line of said first concave reflecting surface are adjusted to produce reflected rays from said second convex reflecting surface having an acute angle of convergence towards the plane of symmetry equal to arctan [2*(L2/L1).sup.2/(1−L2/L1)] relative to the incoming parallel rays in the x-y plane perpendicular to said focal line, and whereby the surface configuration of said second reflecting surface is explicitly and unambiguously determined by the principles of ray optics based on the specified angle of convergence and the result is more uniform illumination of said narrow line of photovoltaic cells since the shadowing effect of said second reflecting surface is reduced resulting in better conversion efficiency of the photovoltaic cells and overall conversion efficiency of the solar collector is optimized.
4. The solar panel of claim 1 having: a. said solar collectors arranged in parallel side-by-side along their long sides such that said axes of rotation of all solar collectors are parallel to each other and are contained in the same plane, and b. said adjustable mount supporting said solar collectors inside said solar panel incorporates a first detent mechanism, which holds said plane of said solar collectors in a position that is tilted in a first direction with respect to said base of said solar panel such that said plane forms an angle, θ, with respect to said base of said solar panel, and c. said adjustable mount supporting said solar collectors inside said solar panel incorporates a second detent mechanism, which holds said plane of said solar collectors in a position that is tilted in a second opposite direction with respect to said base of said solar panel such that said plane forms an angle, θ, with respect to said base of said solar panel, and d. said adjustable mount supporting said solar collectors inside said solar panel incorporates a third detent mechanism, which holds said plane of said solar collectors in a position that is parallel to said base of said solar panel, and e. said plane of said solar collectors has three possible distinct and discrete positions, corresponding to said tilt in said first direction, said tilt in said second direction, and no tilt with respect to said base of said solar panel, and whereby said plane of said solar collectors has three distinct possible orientations in said solar panel that must be selected to maximize electrical energy conversion depending on the angle of incidence of solar rays by selecting the detent position of said mount that minimizes the angle of incidence of solar rays relative to the normal to said plane of said solar collectors.
5. The solar panel of claim 4 further including: a. a drive that is operated by a controller that is programmed to maintain the sun in said plane of bilateral symmetry of each of said solar collectors as a function of time of day and time of year by rotating each of said solar collectors about said axis of rotation, and b. said drive controller adjusts the orientation of said plane of said solar collectors by selecting one of said three detent positions which achieves the smallest angle of incidence of solar rays with respect to the normal to said plane of said solar collectors, and c. said drive controller is programmed to compensate the angle of rotation of said solar collectors whenever the orientation of said plane of said solar collectors is switched from one discrete orientation to another discrete orientation by rapidly slewing the angle of rotation of said solar collectors through a complementary angle to compensate for the change in angle caused by the change in orientation of said plane of solar collectors, and whereby the electrical output of said narrow lines of photovoltaic cells is continuously maximized by centering the concentrated light from said second long reflecting surface on said narrow line of photovoltaic cells and said plane of said solar collectors intercepts a larger cross section of the incident solar light flux thereby minimizing the effects of shadowing on individual solar collectors and maximizing the electrical energy converted at specific times of day and specific times of the year when shadowing of one solar collector by another would otherwise reduce the level of electrical power generation.
6. The solar panel of claim 4 further including: a. a drive that is operated by a servo controller incorporating a feedback loop that continuously maintains the sun in said bilateral planes of symmetry of each of said solar collectors by rotating each of said solar collectors about said axis of rotation, and b. said drive adjusts the orientation of said plane of said solar collectors by selecting one of said three detent positions which achieves the smallest angle of incidence of solar rays with respect to the normal to said plane of said solar collectors, and c. said drive controller automatically compensates the angle of rotation whenever the orientation of said plane of said solar collectors is switched from one discrete orientation to another discrete orientation by rapidly slewing the angle of rotation of said solar collectors through a complementary angle to compensate for the change in angle caused by the change in orientation of said plane of axes, and whereby the electrical output of said narrow lines of photovoltaic cells is continuously maximized by centering the concentrated light from said second long reflecting surface on said line of photovoltaic cells and said plane of said solar collectors intercepts a larger cross sectional area of the incident solar light flux thereby minimizing the effects of shadowing on individual solar collectors and maximizing the electrical energy converted at specific times of day and specific times of the year when shadowing of one solar collector by another would otherwise reduce the level of electrical power generation.
Description
DRAWINGS
Figures
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DETAILED DESCRIPTION
Preferred Embodiment of the Solar Collector—FIGS. 1, 2A, 2B, 5, and 6
(8)
(9) Note that diffuse sky light also illuminates the photovoltaic cells directly without reflecting off the concave surface. Furthermore, diffuse sky light entering the collector from any direction that is in the plane of symmetry of the collector will also be concentrated by the same factor as direct sunlight. Thus this collector also effectively converts diffuse skylight into electrical energy. This is an improvement over many concentrating collectors that do not effectively convert diffuse skylight.
(10)
dy.sub.1/dx=2x (At x=0.5,dy.sub.1/dx=2*0.5=1)
dy.sub.2/dx=20x (At x=0.05,dy.sub.2/dx=20*0.05=1)
A slope of 1 at x=0.5 for the function, y.sub.1, means that the focal point for the surface defined by y.sub.1 is located at y=0.25. This can be seen by the fact that the angle of incidence for a reflected ray relative to the normal to that surface is equal to the angle of reflection. This means that the incoming ray, 25, parallel to the y-axis reflected from the surface y.sub.1 at the point x=0.5 would be reflected parallel to the x-axis and the focal point would be at (x=0, y=0.25) since
y.sub.1(x=0.5)=0.25.
(11) Similarly the focal point for the convex reflecting surface can be shown to be at the same point (x=0, y=0.25) since the slope of the function y.sub.2 is equal to 1 at x=0.05 and
y.sub.2(x=0.05)=10*0.05.sup.2+0.225=0.025+0.225=0.25.
This means that ray, 25, in
(12) As it enters the concave surface, ray, 26, has an x-coordinate of 0.25. It strikes the concave reflecting surface at x=0.25 and is reflected towards the focal point at (x=0, y=0.25). It intercepts the convex reflecting surface, 22, at point (x=0.025, y=10*0.025.sup.2+0.225) and is reflected parallel to the y-axis striking the photovoltaic cell at position x=0.025. Rays parallel to the y-axis between rays 25 and 26 would strike the photovoltaic cell between x=0.025 and x=0.05. Similarly rays striking surface 21 between x=0.05 and x=0.25 would strike the photovoltaic cell at between x=0.005 and x=0.025. By symmetry rays between x=−0.05 and x=−0.5 would strike the photovoltaic cells between x=−0.005 and x=−0.05. This shows that the light intensity striking the photovoltaic cells over these ranges of coordinates is 10 times the flux entering the collector assuming a reflectivity of 1. If the concave, 21, and convex, 22, reflecting surfaces were perfect, the light intensity at the surface of the photovoltaic cell would drop near x=0 due to the shadowing effect of the convex reflecting surface. The intensity can be evened out by flattening the convex reflecting surface slightly. This is an advantage of this collector system. The optical surfaces do not need to be high quality. Some deviation from a perfect parabolic shape is actually desirable to distribute the light intensity more uniformly. This makes inexpensive fabrication possible. Taking the shadowing effect of the convex reflecting surface into account, the flux concentration ratio in
(13) This simple ray analysis does not take into account diffraction effects. It is adequate however for practical dimensions of the collector and for the accuracy needed. Tolerances for the optics are very relaxed because the photovoltaic cells extend over a moderately large area.
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(15) Obviously the actual physical dimensions of the solar collector can be scaled to any appropriate dimensions. It is also possible to vary the angle subtended by the reflecting surfaces as seen from the focal point. For example, the concave reflecting surface, 21, in
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(18) Operation of the Solar Collector in a Solar Panel—
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(22) Advantages of the Preferred Embodiment of the Solar Collector
(23) This preferred embodiment achieves the key goal of minimizing the cost/Watt for electrical power generation. It accomplishes this by enabling an optimized combination of maximum light concentration factor consistent with lowest manufacturing cost. This is possible because the optical and tracking systems are simple and flexible. The optical quality requirements are low because the allowed tolerances are very relaxed. Furthermore this preferred embodiment is very robust. It is compatible with the form factor of a 1-sun solar panel and it can be used wherever this generic panel is used. It does not require expensive unsightly mounts that are much more susceptible to damage and malfunction.
(24) Solar Collector Arrangement to Minimize Shadowing Effects—
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(27) Solar Panel Operation with Minimized Shadowing Effects—
(28) For a given spacing and configuration of solar collectors in a solar panel there will be a limiting angle at which shadowing will start to occur. Lower angles of incidence will result in progressively more shadowing. This limit can be detected with a limit switch which would signal the drive mechanism to toggle the tilt plane to minimize shadowing for these low angles of incidence.
(29) Advantages of Solar Panel Operation with Minimized Shadowing Effects
(30) This enhancement to the configuration of the solar collectors within the solar panel increases the electrical energy conversion in the early daylight hours and in the late daylight hours. Complication of the drive mechanism is minimal.
CONCLUSION, RAMIFICATIONS, AND SCOPE
(31) This invention minimizes the cost/Watt of electrical energy generated including capital equipment expense plus installation and maintenance. Capital expense is minimized because the light concentration ratio can be optimized for maximum leveraging of the photovoltaic cells consistent with very low-cost manufacture of the collectors and the drive mechanism. Installation is no different from installation of a generic 1-sun solar panel. Maintenance is comparable since the drive mechanism is very simple and robust. It also provides maximum flexibility for variations in installation sites and can be used for any and all applications including residential, commercial, and industrial. There are no limitations imposed by weather or aesthetic considerations.
(32) Flexibility is a key attribute of this invention that enables these advantages; consequently, examples presented should not be construed as limiting the scope of this invention. Concentration ratios can be varied over a wide range. Scale of the reflecting surfaces, the photovoltaic cells, and the solar panels can vary over a very wide range from small to large. Deviations of the cross-sections of reflecting surfaces from true parabolas can be employed to improve efficiency. The angle subtended by the concave and convex reflecting surfaces at the focal line can be varied to maximize cost efficiency and/or vary the panel depth requirements. The material used for constructing the reflecting surfaces can be varied in order to achieve the minimum manufacturing cost. This includes use of reflective coatings on transparent materials such as glass.