SOLAR RECEIVER
In one embodiment, a solar receiver has a base plate having a first surface and a second surface, a plurality of solar cells positioned over and supported by the first surface of the base plate, and a multiplicity of fins extending outwardly from the second surface of the base plate. Each of the multiplicity of fins has a fin height axis extending generally perpendicular relative to the base plate, a fin length axis extending generally in parallel with the base plate, and a bottom end attached to the second surface of the base plate, wherein each of the multiplicity of fins are formed from a single, continuous sheet of metal arranged in a serpentine configuration, and wherein each of the multiplicity of fins have a plurality of undulations along the length axis of the fin.
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The present disclosure relates generally to solar receivers. More particularly, the present disclosure relates generally to solar receivers having a heat sink.
BACKGROUND OF THE INVENTIONThe highest cost components of a solar photovoltaic (PV) system are the solar cells that convert sunlight to electricity by the photoelectric effect. To use these cells more effectively, concentrating photovoltaic (CPV) systems focus sunlight from a larger aperture onto a smaller cell area. The waste heat generated in the solar receivers used in CPV systems may raise the cell temperature subjecting the solar cells to thermal stresses causing malfunction, inefficiencies, and increased costs.
Heat sinks may be used to absorb and dissipate the heat from the solar receivers. However, current solar receivers are not sufficiently efficient from a thermal energy transfer standpoint while at the same time sufficiently simple, rugged, compact, and lightweight to be transportable, susceptible to on-site assembly, or efficiently stored.
OverviewA solar receiver is described having a base plate having a first surface and a second surface, a plurality of solar cells positioned over and supported by the first surface of the base plate, each solar cell having a cell face suitable for receiving solar radiation that faces away from the base plate, and a multiplicity of fins extending outwardly from the second surface of the base plate. Each of the multiplicity of fins has a fin height axis extending generally perpendicular relative to the base plate, a fin length axis extending generally in parallel with the base plate, and a bottom end attached to the second surface of the base plate, wherein each of the multiplicity of fins are formed from a single, continuous sheet of metal arranged in a serpentine configuration, and wherein each of the multiplicity of fins have a plurality of undulations along the length axis of the fin.
In another embodiment, the solar receiver may have a base plate having a first surface and a second surface, a plurality of solar cells positioned over and supported by the first surface of the base plate, each solar cell having a cell face suitable for receiving solar radiation that faces away from the base plate, and a multiplicity of fins extending outwardly from the second surface of the base plate. Each of multiplicity of fins has a bottom end opposite a top end, the bottom end attached to the first surface of the base plate, wherein the top end has a width less than a width of the bottom end, wherein each of the multiplicity of fins are formed from a single, continuous sheet of metal arranged in a serpentine configuration, and wherein each of the multiplicity of fins have a plurality of undulations along a length axis of the fin.
Stackable solar receivers are also described with a first solar receiver having a first base plate having a first surface and a second surface, a first plurality of solar cells positioned over the first surface of the first base plate, each solar cell having a cell face suitable for receiving solar radiation that faces away from the first base plate, and a first multiplicity of fins extending outwardly from the second surface of the first base plate, each of the first multiplicity of fins are formed from a single, continuous sheet of metal arranged in a serpentine configuration having a bottom end opposite a top end, the bottom end attached directly to the second surface of the first base plate, wherein the top end has a width less than a width of the bottom end.
The stackable solar receiver also has a second solar receiver having a second base plate having a first surface and a second surface, a second plurality of solar cells positioned over the first surface of the second base plate, each solar cell having a cell face suitable for receiving solar radiation that faces away from the second base plate, and a second multiplicity of fins extending outwardly from the second surface of the second base plate, each of the second multiplicity of fins are formed from a single, continuous sheet of metal arranged in a serpentine configuration having a bottom end opposite a top end, the bottom end attached directly to the second surface of the second base plate, wherein the top end has a width less than a width of the bottom end, wherein the first multiplicity of fins is interleaved with the second multiplicity of fins to stack the first solar receiver with the second solar receiver during transport or storage.
These and other features will be presented in more detail in the following detailed description of the invention and the associated figures.
The accompanying drawings, which are incorporated into and constitute a part of this specification, illustrate one or more example embodiments and, together with the description of example embodiments, serve to explain the principles and implementations.
In the drawings:
Embodiments are described herein in the context of a solar receiver. The following detailed description is illustrative only and is not intended to be in any way limiting. Other embodiments will readily suggest themselves to such skilled persons having the benefit of this disclosure. Reference will now be made in detail to implementations as illustrated in the accompanying drawings. The same reference indicators will be used throughout the drawings and the following detailed description to refer to the same or like parts.
In the interest of clarity, not all of the routine features of the implementations described herein are shown and described. It will, of course, be appreciated that in the development of any such actual implementation, numerous implementation-specific decisions must be made in order to achieve the developer's specific goals, such as compliance with application- and business-related constraints, and that these specific goals will vary from one implementation to another and from one developer to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking of engineering for those of ordinary skill in the art having the benefit of this disclosure.
Heat sinks can be used to absorb and dissipate heat from solar receivers. Heat sinks have a plurality of fins whereby heat generated by the solar cells dissipates by natural free convection through the plurality of fins. This minimizes the temperature rise experienced by the solar cells to improve efficiency and prevent warping, electrical shorts, or any other malfunctions due to high temperatures.
However, forming the plurality of fins illustrated in
Forming a flat and/or squared bottom end 104a, 104b is a challenging task when forming the serpentine configuration. The end result may be a rounded bottom end 104a, a skewed bottom end 104b, or any other non-flat or non-planar configuration.
The various shapes and configurations of the bottom end 104a, b result in a non-uniform gap 108 between the base plate 106 and each of the plurality of fins 102. Thus, more adhesive is necessary to bond the fins 102 to the base plate 106, which increases thermal resistance to the fins 102. Adhesives have less thermal conductivity than the material used to form the base plate and/or the plurality of fins. Thus, the amount of adhesive should be minimized to form a very thin layer of adhesive between the base plate and the heat sink fin to minimize thermal resistance of the bonding layer. Although the use of a adhesive has been used to describe the bond or attachment between the heat sink fin and the base plate, it is not meant to be limiting as any suitable means that enables good thermal conductivity contact between the heat sink fin and the base plate may be used, such as the use of bolts, screws, mechanical fasteners, soldering, brazing, welding or the like.
The thermal conductivity of most adhesives is only approximately 1% that of aluminum. Thus, a larger gap 108 between the base plate 106 and the bottom end 104a, b requires more adhesive to bond the fins 102 to the base plate 106. The use of more adhesive forms a thicker bonding layer 103, which then impedes heat transfer from the base plate 106 to the fins 102. Furthermore, since only a small portion or a small surface area of the bottom end 104a, 104b of the fin 102 is in close contact with the base plate 106, the heat flow or transfer from the base plate 106 to the fin 102 is not symmetric or uniform. More heat flows from the area where the fin 102 is closer to the base plate 106 than the areas where the fin 102 is further away from the base plate 106. As such, there is a higher thermal resistance in the areas where there is more adhesive, such as the areas where the fin 102 is furthest away from the base plate 106. This undesirably reduces the effectiveness of the heat sink and solar receiver 100.
As such, there is a limit to the amount of force that may be applied to the plurality of fins 102. This makes it difficult to obtain a thin adhesive bonding layer between the base plate 106 and the plurality of fins 102 to obtain high thermal conductivity between the base plate 106 and each of the fins 102.
Each fin 202 may also be bent to form a plurality of undulations 204 along a length axis 206 of each of the fins 202. The length axis 206 can extend generally in parallel with the base plate 106. The plurality of undulations 204 creates a wave-like or ruffled configuration to each of the fins 202. Each fin 202 may also have a fin height axis 208 that extends generally perpendicular relative to the base plate. For example, the fin height and fin height axis may be within 100 of the perpendicular to the base plate. In another embodiment, the fin height axis 208 need not be generally perpendicular to the base plate. For example, the fin height axis 208 may vary from a perpendicular axis to the base plate by about 0°-45°.
In one embodiment, each fin 202 may have between about 2 to 10 undulations along the length axis 206. In another embodiment, each fin 202 may have between about 3-6 undulations, and in a specific embodiment, each fin 202 may have between about 4-5 undulations along the length axis 206.
In another embodiment, each fin 202 has between about 2 to 15 peaks 220 and valleys 222 along the length axis 206 of each of the fin 202. In another embodiment, each fin 202 may have between about 3 to 8 peaks 220 and valleys 222 along the length axis 206, and in a specific embodiment, each fin 202 may have at least 4 peaks 220 and valleys 222 along the length axis 206 of each fin 202.
Each of the plurality of undulations 204 may have an undulation pitch 212, which is the distance between each undulation. In one embodiment, the undulation pitch is no greater than approximately one undulation per inch. An undulation amplitude 216 is the depth of the undulation parallel to the base plate 106 and an undulation radius 218 is the radius of the curvature associated with the undulation 204. The heat sink fin 200 may have a fin pitch 214, which is the distance between similar structures on an adjacent fin.
The plurality of undulations 204 forms a heat sink fin 200 having an overall higher stiffness or rigidity that is able to withstand additional pressure during bonding or attachment to the base plate without bowing or breaking of the fins 202. The resulting heat sink fin 200 is more stabilized and able to withstand bending and distortions.
This results in little to no gap between the base plate 106 and the fin 202, which in turn increases thermal conductivity between the base plate 106 and the heat sink fins 200. Furthermore, substantially the entire surface area of the bottom end 206 of each fin 202 is in close contact with the base plate 106.
Since the heat sink fin 200 has an overall higher stiffness or rigidity, it may be bonded or attached to the base plate 106 using a greater force or pressure between the heat sink fin 200 and the base plate 106. This results in a thinner bonding layer 210. Additionally, since each of the bottom ends 206 are substantially planar, the heat sink fin 200 may be bonded to the base plate 106 with a uniform bonding layer 210. Both the thinner and more uniform bonding layer 210 results in decreased thermal resistance at the bonding layer 210 between the heat sink fin 200 and the base plate 106.
The formation of the plurality of undulations along the fin length axis also allows for the use of thinner material to form the heat sink fin since the heat sink fin has an overall higher stiffness or rigidity. This enables the formation of a lighter and less expensive heat sink and solar receiver. Moreover, it has been unexpectedly determined that the fin height may be increased without compromising the mechanical integrity of the heat sink fin. Thus, the fin height 208 to fin length 206 ratio may increase which results in high thermal conductivity since there is more surface area for heat transfer. In one embodiment, the fin height to fin length ratio may be greater than 0.5.
The solar receiver 300 has a multiplicity of fins 308 extending outwardly from the second surface 320 of the base plate 106. Each of the multiplicity of fins 308 has a fin height axis 208 and a length axis 206. The fin height axis 208 can extend generally perpendicular relative to the base plate 106 and the fin length axis 206 can extend generally parallel with the base plate 106. A bottom end of each of the fins 308 can be attached to the second surface of the base plate 106.
The solar cells 306 and multiplicity of fins 308 may be attached or assembled to the base plate by any known means such as those described in co-pending application Ser. No. 12/124,121, entitled “Photovoltaic Receiver”, filed May 20, 2008, which is incorporated herein by reference in its entirety.
In use, the solar cells 306 produce waste heat that must be removed from the solar receiver. The heat may be transferred or transmitted to the base plate 106, through the bonding layer 210 (
Examples are described herein for exemplary purposes only and not intended to be limiting. An example heat sink fin may be made from a continuous sheet of material, such as aluminum. The sheet of material may have a thickness of about 0.020 inches. Each fin may have a fin length of about 5.50 inches and a fin height of about 3 inches. Thus, the ratio of fin height to fin length may be 3 inches/5.5 inches=0.55.
Each fin may have a fin pitch of about 0.25 inches and about 5.5 undulations along the fin length axis. Each fin may have an undulation amplitude of about 0.050 inches, an undulation period of about 1 inch, and an undulation radius of about 1.262 inches. The heat sink may be formed to any desired length. In one embodiment, the heat sink may have a length of about 52 inches, which results in the formation of about 208 fins.
The first multiplicity of fins 418 may extend substantially the entire fin height 208 of the second multiplicity of fins 420 when the first multiplicity of fins 418 are nested within the second multiplicity of fins 420. The combined height of the first solar receiver 414 and the second solar receiver 416 is only slightly greater than the height of one of the solar receivers.
The ability to nest solar receivers increases the packing density of the solar receivers during transportation or storage. In fact, the shipping and storage volume of the solar receivers may be reduced by a factor of two as compared to current shipping and storage volumes where nesting of solar receivers are not possible. As such, concomitant shipping and storage costs may be reduced which can influence the commercial viability of CPV systems.
Furthermore, nesting the solar receivers reduces the probability of fin damage during transportation or storage. The fins form a mechanical protection layer for each opposing fin thereby increasing the mechanical robustness of the structure.
Although
While embodiments and applications of this invention have been shown and described, it would be apparent to those skilled in the art having the benefit of this disclosure that many more modifications than mentioned above are possible without departing from the inventive concepts herein.
Claims
1. A solar receiver, comprising:
- a base plate having a first surface and a second surface;
- a plurality of solar cells positioned over and supported by the first surface of the base plate, each solar cell having a cell face suitable for receiving solar radiation that faces away from the base plate; and
- a multiplicity of fins extending outwardly from the second surface of the base plate, each of the multiplicity of fins having a fin height axis extending generally perpendicular relative to the base plate, a fin length axis extending generally in parallel with the base plate, and a bottom end attached to the second surface of the base plate, wherein each of the multiplicity of fins are formed from a single, continuous sheet of metal arranged in a serpentine configuration, and wherein each of the multiplicity of fins have a plurality of undulations along the length axis of the fin.
2. The solar receiver of claim 1, wherein there are at least four undulations along the length axis of each fin.
3. The solar receiver of claim 1, wherein the plurality of undulations have at least four peaks and four valleys along the length axis of each of the multiplicity of fins.
4. The solar receiver of claim 1, wherein a pitch of each of the plurality of undulations is no greater than approximately one undulation per inch.
5. The solar receiver of claim 1, wherein the multiplicity of fins are made from a metal.
6. The solar receiver of claim 5, wherein the multiplicity of fins are made from aluminum.
7. The solar receiver of claim 1, wherein the bottom end is substantially flat whereby substantially all of a surface area of the bottom end is attached with the second surface of the base plate.
8. The solar receiver of claim 7, wherein the bottom end is attached to the second surface of the base plate with an adhesive.
9. The solar receiver of claim 1, wherein each of the plurality of fins has a top end opposite the bottom end and wherein a width of the top end is less than a width of the bottom end.
10. The solar receiver of claim 1, wherein the top end further comprises an opening to facilitate convective air flow.
11. A solar receiver, comprising:
- a base plate having a first surface and a second surface;
- a plurality of solar cells positioned over and supported by the first surface of the base plate, each solar cell having a cell face suitable for receiving solar radiation that faces away from the base plate; and
- a multiplicity of fins extending outwardly from the second surface of the base plate, each of multiplicity of fins having a bottom end opposite a top end, the bottom end attached to the second surface of the base plate, wherein the top end has a width less than a width of the bottom end, wherein each of the multiplicity of fins are formed from a single, continuous sheet of metal arranged in a serpentine configuration, and wherein each of the multiplicity of fins have a plurality of undulations along a length axis of the fin.
12. The solar receiver of claim 11, wherein the bottom end is substantially flat whereby substantially all of a surface area of the bottom end is attached with the second surface of the base plate.
13. The solar receiver of claim 11, wherein there are at least four undulations along the length axis of each fin.
14. The solar receiver of claim 11, wherein the plurality of undulations have at least four peaks and four valleys along the length axis of each of the multiplicity of fins.
15. The solar receiver of claim 11, wherein the bottom end is attached to the base plate with an adhesive.
16. The solar receiver of claim 11, wherein the multiplicity of fins are made from a metal.
17. The solar receiver of claim 11, wherein the top end further comprises an opening to facilitate convective air flow.
18. Stackable solar receivers, comprising:
- a first solar receiver, having: a first base plate having a first surface and a second surface; a first plurality of solar cells positioned over the first surface of the first base plate, each solar cell having a cell face suitable for receiving solar radiation that faces away from the first base plate; and a first multiplicity of fins extending outwardly from the second surface of the first base plate, each of the first multiplicity of fins are formed from a single, continuous sheet of metal arranged in a serpentine configuration having a bottom end opposite a top end, the bottom end attached directly to the second surface of the first base plate, wherein the top end has a width less than a width of the bottom end;
- a second solar receiver, having: a second base plate having a first surface and a second surface; a second plurality of solar cells positioned over the first surface of the second base plate, each solar cell having a cell face suitable for receiving solar radiation that faces away from the second base plate; and a second multiplicity of fins extending outwardly from the second surface of the second base plate, each of the second multiplicity of fins are formed from a single, continuous sheet of metal arranged in a serpentine configuration having a bottom end opposite a top end, the bottom end attached directly to the second surface of the second base plate, wherein the top end has a width less than a width of the bottom end,
- wherein the first multiplicity of fins is interleaved with the second multiplicity of fins to stack the first solar receiver with the second solar receiver during transport or storage.
19. The solar receivers of claim 18, wherein each of the first and second multiplicity of fins have a plurality of undulations along a length axis of the fin.
20. The solar receivers of claim 19, wherein an undulating pitch and an undulating phase of each of the plurality of undulations are substantially similar.
21. The solar receivers of claim 18, wherein each of the first multiplicity of fins having a first fin height axis extending generally perpendicular relative to the first base plate and wherein each of the second multiplicity of fins having a second fin height axis extending generally perpendicular relative to the second base plate.
22. The solar receivers of claim 21, wherein the first multiplicity of fins extend substantially the entire second fin height of the second multiplicity of fins when the first multiplicity of fins are interleaved within the second multiplicity of fins.
Type: Application
Filed: Dec 19, 2008
Publication Date: Jun 24, 2010
Applicant: Skyline Solar, Inc. (Mountain View, CA)
Inventors: Jason R. WELLS (San Francisco, CA), Khiem B. DO (San Jose, CA)
Application Number: 12/340,379
International Classification: F24J 2/24 (20060101);