Monolithic Mirror Array
The present invention is an improved solar concentrator array utilizing a monolithic array of primary mirrors fabricated from a single sheet of formable material. The material may include glass, plastic, and metal of a high thermal stability to be able to withstand a broad range of temperature conditions. The monolithic array of this invention may include integral alignment or attachment features for attachment to a supporting structure.
1 . A monolithic mirror array comprising:
a single piece of formable material having a first side and a second side;
a plurality of concave surfaces formed in the first side, wherein each of the concave surfaces is substantially parabolic in shape and has a base, and wherein an aperture is located at each base;
a mirror coating deposited on at least a portion of the concave surfaces of the first side; and
a plurality of alignment elements integral to the formable material.
2 . The monolithic mirror array of claim 1 , wherein the plurality of concave surfaces is arranged in a linear array.
3 . The monolithic mirror array of claim 1 , wherein the plurality of concave surfaces is arranged in a planar array.
4 . The monolithic mirror array of claim 1 , wherein the formable material forms a rigid planar structure.
5 . The monolithic mirror array of claim 1 , wherein the formable material is metal.
6 . The monolithic mirror array of claim 1 , wherein the formable material is plastic.
7 . The monolithic mirror array of claim 1 , wherein the formable material is glass.
8 . The monolithic mirror array of claim 1 , wherein the formable material further comprises a filler material.
9 . The monolithic mirror array of claim 1 , wherein a portion of the concave surfaces has a substantially hexagonal perimeter.
10 . The monolithic mirror array of claim 1 , wherein a portion of the concave surfaces has a substantially square shaped perimeter.
11 . A solar energy system comprising:
a monolithic mirror array comprising: a formable material having a first side and a second side; a plurality of concave surfaces formed in the first side, wherein each of the concave surfaces is substantially parabolic in shape and has a base, and wherein an aperture is located at each base; and a mirror coating deposited on at least a portion of the concave surfaces of the first side;
a plurality of receiver devices, each comprising a non-imaging rod and a photovoltaic cell;
a transparent planar surface disposed on the first side of the monolithic mirror array; and
a plurality of convex secondary mirrors mounted to the planar surface, wherein the convex secondary mirrors are located in a position defining a focal region at which light received by the concave surfaces is concentrated onto the photovoltaic cells.
12 . The solar energy system of claim 11 , wherein the monolithic mirror array remains stable within a temperature range of −40 to +200° C.
13 . The solar energy system of claim 11 , wherein the monolithic mirror array further comprises a plurality of alignment elements integral to the formable material.
14 . The solar energy system of claim 11 , wherein the monolithic mirror array further comprises an integral attachment element.
15 . The solar energy system of claim 14 , wherein the attachment element comprises a locking clip disposed on the second side of the monolithic mirror array.
16 . The solar energy system of claim 14 , wherein the attachment element comprises a tubular clip disposed on an edge of the monolithic mirror array.
17 . The solar energy system of claim 13 , wherein the alignment elements comprise a plurality of protruding nubs disposed on the second side of the monolithic mirror array.
18 . The solar energy system of claim 11 , further comprising two or more of the monolithic mirror arrays.
19 . The solar energy system of claim 11 , wherein the monolithic mirror array, the planar surface, and the receiver devices form a hermetically sealed enclosure.
20 . The solar energy system of claim 11 , wherein the plurality of receivers fit integrally into the apertures at the base of the concave surfaces.
21 . The solar energy system of claim 11 , further comprising a backpan fixedly mounted to the monolithic mirror array.
22 . The solar energy system of claim 14 , further comprising a backpan fixedly mounted to the monolithic mirror array via the integral attachment element.
23 . A solar energy device comprising:
a monolithic mirror comprising:
a single piece of formable material having a first side and a second side;
a concave surface formed in the first side, wherein the concave surface is substantially parabolic in shape and has a base and wherein an aperture is located at the base;
a mirror coating deposited on at least a portion of the concave surface of the first side; and
an attachment element integral to the formable material.
24 . The solar energy device of claim 23 , further comprising:
a receiver device comprising a non-imaging rod and a photovoltaic cell;
a substantially transparent planar surface disposed on the first side of the monolithic mirror; and
a convex secondary mirror mounted to the planar surface, wherein the convex secondary mirror is located in a position defining a focal region at which light received by the concave surface is concentrated onto the photovoltaic cell.