The present invent relates to a method of packing a solar collector and a structure thereof, and more particularly to a method of packing ball lens of a solar collector and a structure thereof which applies the ball lens as a secondary optical element and eliminates a support component for supporting the ball lens.
Solar power is collected by a solar cell on which sunlight is illuminated. To enhance power efficiency, condenser lens is fixed in a concentrated solar module so as to collect light energy effectively. The concentrated solar collector module contains a solar collector for collecting sunlight and is produced automatically, wherein at least one collar cell is mounted in the solar collector, and its size is decreased to save production material and cost.
For example, a solar cell is applied to match with a secondary optical element, such as a ball lens, to reduce a light focus point, increase sunlight irradiating angle, and shorten focal distance. However, a conventional method of fixing the ball lens cannot obtain these purposes.
As shown in
As illustrated in
Due to sunlight is influenced by water vapors and suspended solids in air and condenser lens, it cannot focus effectively to generate stray light. In addition, the stray light, which does not irradiate on the ball lens, cannot be absorbed by the solar cell, thus losing working efficiency of the solar collector module.
Accordingly, weight, part quantity and simplified structure are necessary for miniaturizing concentrator solar cell module. Also, the stray light has to be collected and used to enhance working efficiency of the solar collector module.
The present invention has arisen to mitigate and/or obviate the afore-described disadvantages.
The primary object of the present invention is to provide a method of packaging ball lens of a solar collector which contains step of coating optical clear adhesives on colloid layers twice, and the optical clear adhesives are solidified so that a solar cell, plural gold wires, and an electric circuit are packaged, thereafter optical clear adhesive is coated again to position the ball lens, such that the ball lens will not deposit downwardly to press and damage the plural gold wires.
Further object of the present invention is to provide a structure of packaging ball lens of a solar collector, which after the ball lens is positioned by ways of optical clear adhesive, a conventional support component is eliminated to lower weight of the solar collector and to decrease energy consumption resulting from chasing sun.
Another object of the present invention is to provide a structure of packaging ball lens of a solar collector which contains a dam used in step of coating optical clear adhesive in second time so that the optical clear adhesive is limited within a certain range to enhance a coating area; hence stray light, which does not irradiate on the ball lens, is guided to illuminate the solar cell so as to increase working efficiency of the solar collector.
To obtain the above objective, a method of packaging ball lens of a solar collector steps of: fixing a solar cell on a substrate; forming a first colloid layer on the substrate and covering the solar cell by using the first colloid layer; solidifying the first colloid layer; forming a second colloid layer on the first colloid layer; arranging a ball lens on the second colloid layer; and solidifying the second colloid layer.
With reference to
S10: fixing a solar cell on a substrate;
S11: forming a first colloid layer on the substrate and covering the solar cell by using the first colloid layer;
S12: solidifying the first colloid layer;
S13: forming a second colloid layer on the first colloid layer;
S14: arranging a ball lens on the second colloid layer; and
S15: solidifying the second colloid layer.
After the solar cell, plural gold wires and an electric circuit, which are located below the ball lens, are packaged and solidified by the first colloid layer, the ball lens is positioned by solidifying the second colloid layer, such that the ball lens will not deposit downwardly to press and damage the plural gold wires when using one-time coating to coat the first colloidal layer and the second colloidal layer.
With reference to
In addition, a first colloid layer 21 is formed on the substrate 10 and has optical clear adhesive coated thereon so as to cover the solar cell 11, such that the first colloid layer 21 packages and protects the solar cell 11, the electric circuit 12, and the plural gold wires 13, thus preventing aging and corrosion of the solar cell 11, the electric circuit 12, and the plural gold wires 13. Also, the solar cell 11 can receive sunlight efficiently. It is to be noted that since the optical clear adhesive is a substance with liquidity, it solidifies after being irradiated by ultraviolet (UV) to package the solar cell 11. The optical clear adhesive can be also solidified by being placed at room temperature environment or by ways of heating means, etc.
The second colloid layer 22 has optical clear adhesive coated thereon and is applied to position a ball lens 3 above the solar cell H, so a coating amount of the optical clear adhesive of the second colloid layer 22 is less than that of the first colloid layer 21, such that the second colloid layer 22 partially covers the first colloid layer 21, and the ball lens 3 is coupled with the first colloid layer 21.
When the ball lens 3 is placed on the second colloid layer 22, and the second colloid layer 22 does not solidified, a fixture 4 is used to position the ball lens 3 auxiliary, wherein the fixture 4 includes a plurality of orifices 41 defined thereon so as to receive the ball lens 3, and a diameter of each orifice 41 is larger than that of the ball lens 3, such that when the ball lens 3 is placed into one of the plurality of orifices 41, it is positioned above the solar cell 11 by the fixture 4, and then ultraviolet (UV) irradiates and solidifies the second colloid layer 22 so that the ball lens 3 is positioned on the second colloid layer 22, thereafter the fixture 4 is removed, thus packaging the ball lens of the solar collector as shown in
With reference to
In this embodiment, after the first colloid layer 21 is solidified on the substrate 10, the dam 5 is placed on the substrate 10. The dam 5 surrounds the first colloid layer 21 and is made of any one of optical clear adhesive, silicone and epoxy. Taking this optical clear adhesive for example, it is pre-solidified and is placed on the substrate 10. The dam 5 is not a support component for supporting the ball lens 3 like a conventional 0-ring, and it is capable of being expanded based on an area of the second colloid layer 22 and is away from a central position of the solar collector.
After placing the dam 5, the optical clear adhesive is filled into the dam 5 to form the second colloid layer 22, such that the second colloid layer 22 covers the first colloid layer 21, and the dam 5 has a light absorbing face 23 defined therein. A fixture 4 is served to position the ball lens 3, and the second colloid layer 22 solidifies to position the ball lens 3, thereafter the fixture is removed to finish package of the ball lens of the solar collector as illustrated in
As shown in
With reference to
With reference to
Thereby, the optical clear adhesives are coated on the colloid layers twice and are solidified so that the solar cell, the plural gold wires, and the electric circuit are packaged, thus eliminating use of a conventional support component, lowering weight of the solar collector, and simplifying the solar collector. Moreover, the dam is applied to absorb stray light to enhance light absorption of the solar cell and working efficiency of the solar collector.
While the preferred embodiments of the invention have been set forth for the purpose of disclosure, modifications of the disclosed embodiments of the invention as well as other embodiments thereof may occur to those skilled in the art. Accordingly, the appended claims are intended to cover all embodiments which do not depart from the spirit and scope of the invention.