Effects of manufacturing tolerances on micro-CPV module performance

In micro-concentrating photovoltaics (micro-CPV), the size of solar cells is reduced (<1x1 mm2) compared to conventional CPV. However, the quantity and requirement for placement accuracy of solar cells is increased. To be economically competitive, a promising possibility for the die assembly is a high throughput and relatively unprecise pick and place process combined with surface tension-driven self-alignment of the liquid solder. In this article, this approach is experimentally investigated, with a focus on the influences of solder volume, receiving pad layouts, and initial displacements of the cells on the self-alignment accuracy. Here, we show that an induced motion due to the initial displacement of the cells or due to solder flow along tracks leads to a more robust and accurate process. We found that less solder and rather smaller pads than cells (here by 92 μm or 10.4% of the cell length) are beneficial for self-alignment accuracy. However, for micro-CPV, conductor tracks connected to the pad are required for electrical interconnection and heat dissipation. Here, all cells are self-aligned and reach an accuracy between −15 and +15 μm, which is mainly due to the cell-to-pad size difference. Optical simulations show that this displacement would lead to an optical loss of 0.1%abs instead of 12.1%abs when displacing the cell by 150 μm. Thus, the self-alignment using the surface tension of the liquid solder leads to sufficient accuracy.

Forced Motion Activated Self-Alignment of Micro-CPV Solar Cells

In order to increase the potential of multi junction based concentrator photovoltaics (CPV), AZUR SPACE Solar Power GmbH is developing the next generation, III-V five junction solar cells. To assess the performance of these 5C46 solar cells, it is required to develop an appropriate measurement system which is not only capable of determining distinctive parameters such as short-circuit current, open-circuit voltage and efficiency for concentrations of up to 1000 suns, but also allows a commercially attractive throughput. To achieve these requirements, the pulsed solar simulators at AZUR SPACE were upgraded with additional spectral filters. With the help of the additional optical filters, it is possible to match the irradiation spectrum to the desired AM1.5d conditions. Finally, an adaptation of the established calibration procedure is presented to enable the customer to bin cells for maximum performance under operating conditions in the module. 

Spectrally accurate calibration of pulsed solar simulators for multi-junction CPV measurements

Two-step nested optical-electrical Monte-Carlo approach to analyze the influence of tolerances on Micro-CPV module performance

Effect of manufacturing tolerances on Micro-CPV assemblies: A quantitative approach based on statistical modeling

With the 5C46 AZUR SPACE is introducing its new CPV cell into the market. This upright metamorphic AlInGaP/InGaP/AlInGaAs/InGaAs/Ge 5-junction cell uses sub-cell materials comparable to AZUR’s 4G32 space solar cell but has an additional InGaP junction. The cell design is laid out for optimum module performance at operating conditions. As reported earlier, the bandgaps of the sub-cells have been selected to avoid the dips in the AM1.5d spectrum for cell temperatures up to 90°C. The optimization of the 5C46 has been monitored by the manufacture of 5C46-based commercial CPV modules equipped with secondary lenses and rating of these modules at Fraunhofer ISE. A very good efficiency of 31.7% at Concentrator Standard Operating Conditions (CSOC, lens array aperture) has been reached corresponding to a power boost of 17.5% compared to reference modules equipped with 3C44 cells. In the last optimization step, the thicknesses of the sub-cells have been adjusted to achieve current matching under operating conditions on module level. The paper describes the method used for modelling and the calculation of the optimum thicknesses. It involves the determination of the absolute quantum efficiency of the bare cell and accounts for the thermal band-gap shifts as well as the optical effects due to mounting of the secondary and the transmission of the primary lens. First outdoor results of modules equipped with the final 5C46 design confirm that the current-matching for operating condition on module level was successfully achieved by the described method. 

AZUR’s new 5C46 CPV cell: Final design for optimized outdoor performance

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AZUR’s new 5C46 CPV cell: Final design for optimized outdoor performance