High accuracy module assembly process

Abstract

The present invention relates to an assembling method for a base plate of a concentrated photovoltaic module comprising the steps of: assembling a heat sink on the base plate; and assembling a photovoltaic cell assembly on the heat sink after the heat sink has been assembled on the base plate.

The invention claimed is: 
     
       1. A method comprising the steps of:
 assembling a heat sink on a base plate of a concentrated photovoltaic module; and 
 assembling a photovoltaic cell assembly on the heat sink after the heat sink has been assembled on the base plate; 
 wherein the method further comprises a step of marking the heat sink, once assembled on the base plate, with position markings indicating a mounting position of the photovoltaic cell assembly; 
 wherein the step of assembling the photovoltaic cell assembly on the heat sink is carried out by using the position markings for the alignment of the photovoltaic cell assembly. 
 
     
     
       2. The method according to  claim 1 , wherein the photovoltaic cell assembly comprises a photovoltaic cell. 
     
     
       3. The method according to  claim 2 , wherein the photovoltaic cell assembly further comprises a semiconductor structure on which the photovoltaic cell is assembled. 
     
     
       4. The method according to  claim 3 , further comprising the step of assembling the photovoltaic cell on the semiconductor structure with a semiconductor manufacturing process. 
     
     
       5. The method according to  claim 4 , wherein the step of marking the heat sink comprises marking the heat sink with position markings based on a position of a lens of the concentrated photovoltaic module. 
     
     
       6. The method according to  claim 5 , wherein the position marking is obtained by a laser. 
     
     
       7. The method according to  claim 5 , wherein the position of a lens is determined with respect to a common reference point between a lenses layer and the base plate. 
     
     
       8. The method according to  claim 7 , wherein the assembling of the photovoltaic cell assembly on the heat sink is realized by means of gluing and/or laser welding. 
     
     
       9. The method according to  claim 1 , wherein the step of marking the heat sink comprises marking the heat sink with position markings based on a position of a lens of the concentrated photovoltaic module. 
     
     
       10. The method according to  claim 3 , wherein the step of marking the heat sink comprises marking the heat sink with position markings based on a position of a lens of the concentrated photovoltaic module. 
     
     
       11. The method according to  claim 1 , wherein the assembling of the photovoltaic cell assembly on the heat sink is realized by means of gluing and/or laser welding. 
     
     
       12. A method of aligning a photovoltaic cell assembly with a heat sink, the method comprising:
 assembling a heat sink on a base plate of a concentrated photovoltaic module;   marking the heat sink with position markings indicating a mounting position of the photovoltaic cell assembly; and   assembling the photovoltaic cell assembly on the heat sink using the position markings for alignment of the photovoltaic cell assembly.   
     
     
       13. A concentrated photovoltaic module, comprising:
 a heat sink supported on a base plate;   a photovoltaic cell assembly supported on the heat sink; and   a lens supported over the photovoltaic cell assembly;   wherein the heat sink comprises at least one position marking aligned with the photovoltaic cell assembly, the at least one position marking indicating a mounting position of the photovoltaic cell assembly on the heat sink.   
     
     
       14. The concentrated photovoltaic module of claim 13, wherein the at least one position marking comprises:
 a first position marking having a corner shape, the corner shape of the first position marking aligned with two sides of the photovoltaic cell assembly; and   a second position marking having a cross shape, the cross shape of the second position marking underlying the photovoltaic cell assembly.   
     
     
       15. The concentrated photovoltaic module of claim 13, wherein the photovoltaic cell assembly comprises a photovoltaic cell supported on a semiconductor structure, the semiconductor structure comprising one or more of a bypass diode and all necessary electrical connections for the photovoltaic cell. 
     
     
       16. The concentrated photovoltaic module of claim 15, wherein a tolerance for placement of the photovoltaic cell assembly on the heat sink is in a range of micrometers or lower. 
     
     
       17. The concentrated photovoltaic module of claim 13, wherein the photovoltaic cell assembly is affixed to the heat sink by glue or a weld. 
     
     
       18. The concentrated photovoltaic module of claim 13, wherein the heat sink is affixed to the base plate by glue, a weld, or screws. 
     
     
       19. The concentrated photovoltaic module of claim 13, wherein the lens comprises one or more transparent, nonfocusing regions. 
     
     
       20. The concentrated photovoltaic module of claim 19, wherein the one or more transparent, nonfocusing regions are aligned with the at least one position marking of the heat sink. 
     
     
       21. The concentrated photovoltaic module of claim 13, wherein the lens is configured to focus all incoming light in a region corresponding to placement of the photovoltaic cell assembly on the heat sink. 
     
     
       22. The concentrated photovoltaic module of claim 13, wherein the lens is configured to vertically focus rays going through a center of the lens. 
     
     
       23. The concentrated photovoltaic module of claim 13, wherein a focal distance of the lens at wavelengths for a laser corresponds to a top plane of the heat sink and the focal distance of the lens at wavelengths for sunlight corresponds to a top plane of the photovoltaic cell assembly. 
     
     
       24. An intermediate product in a process of forming a concentrated photovoltaic module, comprising:
 a heat sink supported on a base plate;   wherein the heat sink comprises at least one position marking indicating a mounting position for a photovoltaic cell assembly on the heat sink; and   wherein the heat sink lacks a photovoltaic cell assembly supported on the heat sink, wherein a lens is supported over the heat sink, and wherein the lens comprises one or more transparent, nonfocusing regions.   
     
     
       25. The intermediate product of claim 24, wherein the at least one position marking comprises:
 a first position marking having a corner shape, the corner shape of the first position marking aligned with a desired position for two sides of the photovoltaic cell assembly; and   a second position marking having a cross shape, the cross shape of the second position marking underlying the mounting position for the photovoltaic cell assembly.   
     
     
       26. The intermediate product of claim 24, wherein the heat sink is affixed to the base plate by glue, a weld, or screws. 
     
     
       27. The intermediate product of claim 24, wherein the one or more transparent, nonfocusing regions are aligned with the at least one position marking of the heat sink. 
     
     
       28. The intermediate product of claim 24, wherein the lens is configured to focus all incoming light in a region corresponding to desired placement of a photovoltaic cell assembly on the heat sink. 
     
     
       29. The intermediate product of claim 24, wherein the lens is configured to vertically focus rays going through a center of the lens.