CONCENTRATED PHOTOVOLTAICS (CPV)

INTRODUCTION
Spurred by the 1973 oil crisis, research on concentrating PV systems began in earnest in 1975 [1]. The main idea is simple: to concentrate solar light using cheap optical elements such as mirrors or lenses over much smaller (down to 1/1000), and that to reduce the costs of installed power (and thus the costs of produced energy). This cost reduction can be met using cheap materials for the optics and modules, e.g. molded plastic, glass or aluminum [2]. Notwithstanding this apparent simplicity, the expected high efficiency can be reached only mastering the several scientific and technological fields involved. Thus, the study of concentrated photovoltaics has as a result not only the prototype of an innovative module, but also an interdisciplinary knowledge useful in other applications. The interdisciplinary competencies maturated within this project have a natural application into lighting techniques, LED, thermal solar (CSP) and hybrid automotive. Since the efficiency of CPV concentrator depends on the solar spectrum, the precise measurement of the spectrum and its dependency on pollution is of great importance for CPV, and can have as result also the prototyping of optical sensors for polluting agents. The study of triple junction (3J) solar cells has already given as a spin-off result the feasibility study and prototyping of a modular optically powered floating HV (up to 2 MV) generator [3]. The CPV technology is mainly based on triple junction solar cells, that have very high efficiency (more than 40%, still increasing). Differently from silicon solar cells, on 3J the Suns light can be concentrated up to 2000 times, without loss of efficiency (efficiency increases in fact). The structure of the 3J cells is shown in Figure 1. This structure allows to the cells to convert al larger part of the solar spectrum, relative to the span possible to silicon or thin film.

Figure 1. The structure of the triple junction solar cells.

The high concentration allows the use of very small cells: in our case a concentrator has a projected area of 360 cm2, and with a concentration factor of 600 times it feeds two 0.3 cm2 3J solar cells. Goal of this research are the design and prototyping of a CPV system, using concentrators made of molded plastic mirrors. The first three years of the project resulted in several prototypes, the last one used in four demonstrators (18 kWp) already working.

The scientific work done so far resulted in solar modules with in-filed efficiency of 23.6% average, higher that several competitors. Moreover, several prototypes with efficiency larger than 25% (state of the art result) have already been made. Thanks to the support of Centro Fermi it was possible to involve into the project three important companies, which intend to bring the prototype into production. The personnel involved into this project are among the founders of the Photovoltaics Center funded by Padua University and Veneto Region.

PRINCIPAL GOALS ACHIEVED

During the last years it has been possible to develop and test several configurations of concentrating photovoltaics modules. They are innovative, with high concentration factor (600X) and high efficiency (up to 25%), patent pending [2]. Different optical configurations have been developed and tested, each time with an increase in efficiency. The final configuration of the optics, used to build the larger modules is shown in Figure 2. It is a non-imaging optics system (the shape of the solar disc is not conserved, in order to ensure a larger power homogeity over the solar cell)[5]. Figure 3 shows the uniformity of the power over the 3J cell. A very homogeneous power profile over the cell is extremely important for the efficiency of the module, and its reliability.

Figure 2. The optics developed has a symmetric structure. Each of the two mirrors is divided into four different sectors to increase the homogeneity of the illumination.

Figure 3. Homogeneity of the power over the 3J solar cell.

Figure 4 shows an example of a molded plastic concentrator, developed within this project. The concentrator is made of two symmetric mirrors, each concentrating the light on a 3J solar cell, placed opposite. Glued to each of the cells is a quartz homogenizer (called the secondary optics),
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that is needed to increase the acceptance angle (the maximum misalignment angle still giving 90% of the maximum power) and is needed to have a more homogeneous power profile over the cell. Figure 5 shows one of these secondary optics elements, glued to the 3J solar cell, illuminated by the concentrated Suns light.

Figure 4. Picture of a concentrator. It is of molded plastic, metallized with aluminum to have 90% reflectance.

Figure 5. Quartz secondary optics used to increase acceptance angle and homogeneity of power over the solar cell.

Such a high concentration (600X) can result in a too high temperature of the cells: a very accurate study of the heat sink is necessary [6], otherwise the efficiency of the cell (which decreases linearly with increase of temperature, at a rate of -0.06%/K) will be too low. Several heat sinks have been numerically simulated and then validated with experiments. One example of numerical simulation is shown in Figure 6.

Figure 6. Example of a numerical simulation of a heat sink. It keeps the temperature of the 3J solar cell under 80 C in normal operation.

Figure 7. Measurement of efficiency, December 12, 2011. Efficiency reached 23%, blue line. Black line is the measurement of the Direct Normal Irradiation (DNI), in W/m2.

The measurements made on the first module resulted in several modifications, implemented in further modules, built at the end of 2011. Some of these newer modules were tested; a measurement is shown in Figure 7. After that, other modules were made, realizing 18 kWp (Figures 8 to 10). The concentrators developed for these systems have average efficiency of 23,6%, the best samples have efficiency more than 25.5%. The efficiency of these modules were measured. Average values are 23,6% (same as concentrators), and best modules more than 24%. The study of the triple junction solar cells resulted to a feasibility study and a prototype of a modular optically powered floating HV generator [3].
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Figure 8. Prototype of a CPV system. Four of these systems have been installed in August 2012, to an installed power of 18 kWp.

Figure 9. Zoom of the CPV system.

Figure 10 . Another view of the CPV system. 4/6

PRINCIPAL GOALS TO REACH

The main goals in the near future are related to: i) the optimization of the system already realized, using the various lessons learned and the future research; ii) the development of a new innovative optical system, which will have efficiency higher than 26%. The concentrating factor will be doubled, in order to reduce the production costs. A CAD rendering of the new module (a draft, so far) is shown in Figure 11. More innovative optical systems will also be developed; Figure shows a CAD rendering of the most probable system. The aim is to produce a module with efficiency as high as 26.5%, a value at the state of the art.

Figure 11. CAD rendering of the optimized concentrator, 1000X of concentrating factor.

Figure 12. CAD rendering of the innovative optical design, concentrating factor 1000X.

COLLABORATIONS
The realization of this project would have been very difficult without the collaborations with the Department of Physics of Padua University and with a group of companies very active in the field of plastic molding for the automotive sector (among them Unitek srl, San Vendemiano - TV). At the end of 2011 we took part to the creation of the Photovoltaic Pole of Veneto Region (http://www.polofotovoltaicoveneto.it/), funded by Padua University and Veneto Region. This Pole has a work package (WP3) entirely dedicated to the concentrated photovoltaics.

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Finally, Dr. Antonini collaborated to a proposal of a strategical project for the University of Padua with the title: A Knowledge-Based Platform for Innovation Promotion and Assessment: The Case of Biofuels in Veneto Region, whose evaluation will occur in 2013.

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ESSENTIAL BIBLIOGRAPHY
[1] R. M. Swanson: The promise of concentrators. Progress in Photovoltaics: Research and Applications, 8, 93-111 (2000). [2] P. Antonini et al: Modular Concentrator, Particularly For Photovoltaic Solar Panels; Patent Pending. [3] P. Antonini et al: A modular optically powered floating HV generator, accepted in Rev. Sci. Instrum. (2013). [4] P. Antonini: Concentrated Photovoltaics: is it a real opportunity? Lecture Notes of the International School on Energy 2012. [5] R. Winston, J. C. Miano, P. Bentez: Nonimaging Optics, Elsevier (2005). A. Luque, G. Sala, J.C. Arborio: Electric and thermal model for non-uniformly illuminated concentration cells. Solar Energy Materials and Solar Cells 51, 269-290 (1998). [6] A. Royne, Ch. J. Dey, D. R.Mills: Cooling of photovoltaic cells under concentrated illumination: a critical review. Solar Energy Materials and Solar Cells 86, 451-483 (2005). [7] IEC 62108:2007, International Standard: Concentrator Photovoltaic (CPV) modules and assemblies Design qualification and type approval. International Electrotechnical Commission. Geneva. CH. www.iec.ch. [8] www.polofotovoltaicoveneto.it

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