US4971633A
Expired / Lapsed
US
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Photovoltaic cell assembly
Assignee: United States Department of Energy
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Filing: 1989-09-26
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Granted: 1990-11-20
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Expires: 2009-09-26
Abstract
Abstract A photovoltaic assembly for converting high intensity solar radiation intolectrical energy in which a solar cell is separated from a heat sink by a thin layer of a composite material which has excellent dielectric properties and good thermal conductivity. This composite material is a thin film of porous Al 2 O 3 in which the pores have been substantially filled with an electrophoretically-deposited layer of a styrene-acrylate resin. This composite provides electrical breakdown strengths greater than that of a layer consisting essentially of Al 2 O 3 and has a higher thermal conductivity than a layer of styrene-acrylate alone.
Inventors
- 👤 Leonard C. Beavis
- 👤 Janda K. G. Panitz
- 👤 Donald J. Sharp
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-09 13:33
CPC Classifications
H; H10; H10F; H10F77/00; H10F77/60; H10F77/63; Y; Y02; Y02E; Y02E10/00; Y02E10/50
Claims Analysis
Total Claims: 18
Claim 1
Independent Claim
97 words
A photovoltaic assembly for converting high intensity solar radiation into electrical energy comprising: (a) a base comprising a thermally-conductive backing plate and a composite, thermally-conductive dielectric layer integral with a surface of said backing plate, said composite thermally-conductive dielectric layer comprising a thin film of porous Al 2 O 3 and an electrophoretically-deposited styrene-acrylate resin within the pores of said film of porous Al 2 O 3 ; and, (b) a plurality of photovoltaic cells in thermal contact with said composite thermally-conductive dielectric layer, whereby heat generated in said photovoltaic cell is transmitted to said backing plate.
Claim 2
Dependent Claim
97 words
A photovoltaic assembly for converting high intensity solar radiation into electrical energy comprising: (a) a base comprising a thermally-conductive backing plate and a composite, thermally-conductive dielectric layer integral with a surface of said backing plate, said composite thermally-conductive dielectric layer comprising a thin film of porous Al 2 O 3 and an electrophoretically-deposited styrene-acrylate resin within the pores of said film of porous Al 2 O 3 ; and, (b) a plurality of photovoltaic cells in thermal contact with said composite thermally-conductive dielectric layer, whereby heat generated in said photovoltaic cell is transmitted to said backing plate.
Claim 3
Dependent Claim
22 words
An assembly according to claim 1 wherein said backing plate comprises a metal selected from aluminum, aluminum alloys, copper, and copper alloys.
Claim 4
Dependent Claim
19 words
An assembly according to claim 1 wherein said electrophoretically-deposited resin is a styrene-acrylate copolymer cross-linked with a melamine group.
Claim 5
Dependent Claim
26 words
An assembly according to claim 1 wherein the thickness of said thin film of porous Al 2 O 3 is about 0.5 to about 50 microns.
Claim 6
Dependent Claim
26 words
An assembly according to claim 1 wherein the thickness of said thin film of porous Al 2 O 3 is about 10 to about 30 microns.
Claim 7
Dependent Claim
26 words
An assembly according to claim 1 wherein the thickness of said thin film of porous Al 2 O 3 is about 20 to about 25 microns.
Claim 8
Dependent Claim
41 words
An assembly according to claim 1 wherein said electrophoretically-deposited resin within the pores of said film of Al 2 O 3 has a thickness of about 10 to 100% of the thickness of said film of Al 2 O 3 .
Claim 9
Dependent Claim
41 words
An assembly according to claim 1 wherein said electrophoretically-deposited resin within the pores of said film of Al 2 O 3 has a thickness of about 90 to 100% of the thickness of said film of Al 2 O 3 .
Claim 10
Dependent Claim
32 words
An assembly according to claim 1 wherein said composite, thermally-conductive dielectric layer exhibits a breakdown voltage of at least about 2,000 volts and a thermal conductivity of at least about 0.5 watts/meter-°Kelvin.
Claim 11
Dependent Claim
33 words
An assembly according to claim 1 wherein said composite, thermally-conductive dielectric layer exhibits a breakdown voltage of at least about 5,000 volts and a thermal conductivity of about 0.5 to about 0.8 watts/meter-°Kelvin.
Claim 12
Independent Claim
101 words
A method of making a photovoltaic assembly for converting high intensity solar radiation into electrical energy comprising: (a) forming a thin film of porous Al 2 O 3 on a surface of a thermally-conductive backing plate; (b) contacting the resulting film of Al 2 O 3 with an electrophoretic bath of a styrene-acrylate resin under conditions which result in the pores of said film being deposited within said resin, thereby forming a composite, thermally-conductive dielectric layer on said backing plate; (c) curing the resulting electrophoretically deposited resin; and, (d) affixing a plurality of photovoltaic cells to said composite, thermally-conductive dielectric layer.
Claim 13
Independent Claim
101 words
A method of making a photovoltaic assembly for converting high intensity solar radiation into electrical energy comprising: (a) forming a thin film of porous Al 2 O 3 on a surface of a thermally-conductive backing plate; (b) contacting the resulting film of Al 2 O 3 with an electrophoretic bath of a styrene-acrylate resin under conditions which result in the pores of said film being deposited within said resin, thereby forming a composite, thermally-conductive dielectric layer on said backing plate; (c) curing the resulting electrophoretically deposited resin; and, (d) affixing a plurality of photovoltaic cells to said composite, thermally-conductive dielectric layer.
Claim 14
Dependent Claim
42 words
A method according to claim 11 wherein said backing plate comprises an aluminum-containing member, and said thin film of Al 2 O 3 is formed on said backing plate by electrolytically oxidizing a surface of said aluminum-containing member in an anodizing bath.
Claim 15
Dependent Claim
17 words
A method according to claim 12 wherein said anodizing bath is an aqueous solution containing chromic acid.
Claim 16
Dependent Claim
17 words
A method according to claim 12, wherein said anodizing bath is an aqueous solution containing sulfuric acid.
Claim 17
Dependent Claim
13 words
A method according to claim 11 wherein said styrene-acrylate resin contains a melamine.
Claim 18
Dependent Claim
34 words
A method according to claim 11 wherein said styrene-acrylate resin is cured by heating to a temperature of about 160° to about 220° C. for a period of about 20 to about 30 minutes.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1993-11-19 | 1994-05-21 | 1994-11-20 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1997-11-19 | 1998-05-21 | 1998-11-20 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2001-11-19 | 2002-05-21 | 2002-11-20 | $7700.00 | Window Closed / Lapsed |