Semiconductor solar cell package
A package for a solar cell is provided having laminates formed by stacked lead frames to form an integral package supporting a solar cell structure. Lead frames serve as a heat sink, raised portions match a cavity in a middle lead frames that contain and hold individual solar cell chips in place. Beveled interior edges of a carrier lead frame are in electrical contact with bus bars on the periphery of a suspended solar cell and form the electrical connection for the cell, maximizing current handling capability and allowing the use of spring tension and/or a bonding compound for additional connection strength and integrity. Such a “stackable” semiconductor package requires no ribbon bonding and has multiple bias options, maximum scalability, enhanced moisture resistance, and multiple attachment options for heat sink attachment.
1. An assembly, comprising:
a first electrically conductive layer, wherein the first electrically conductive layer is electrically conductive and comprises:
a first top surface;
a first bottom surface;
a first ledge extending from the first top surface and edges defining a first window; and
a first cavity within the lower surface, wherein the first cavity is bounded by the first ledge and is aligned with the first window;
a photovoltaic device disposed within the first cavity, wherein the photovoltaic device comprises:
a top an upper surface comprising a cathode, wherein the cathode is electrically connected to the first ledge; and
bottom surface comprising an anode;
a first insulating material underlying the bottom surface of the first electrically conductive layer and extending into a portion of the first cavity;
a second electrically conductive layer underlying the first insulating material, wherein the second electrically conductive layer comprises:
a second top surface;
a second bottom surface;
a first raised portion, wherein the first raised portion is disposed within the first cavity and comprises a second ledge extending from the second top surface and defining a second window, wherein,
the second ledge is electrically connected to the anode; and
the second electrically conductive layer is electrically insulated from the first electrically conductive layer by the first insulating material; and
a second cavity within the first raised portion and aligned with the first cavity and with the second window; and
a third layer underlying the second electrically conductive layer, wherein,
the third-layer comprises a second raised portion; and
the second raised portion is disposed within the second cavity; and
a top surface of the second raised portion is in thermal contact with the bottom surface of the photovoltaic device.
2. The assembly of claim 1 , wherein the third layer is thermally conductive and electrically insulating.
3. The assembly of claim 1 , wherein the third layer is electrically conductive.
4. The assembly of claim 1 , comprising a second insulating material disposed between a portion of the second layer and the third layer, wherein the second layer is electrically insulated from the third layer.
5. The assembly of claim 1 , comprising an index matching material disposed within the first window and coating the top surface of the photovoltaic device.
6. The assembly of claim 1 , comprising a thermal interface material disposed between the bottom surface of the photovoltaic device and the second raised portion of the third layer.
7. The assembly of claim 1 , wherein the first layer comprises fingers interconnecting the cathode of the photovoltaic device to terminals on a printed circuit board and to bypass diodes.
8. The assembly of claim 1 , wherein each of the first layer, the second layer, and the third layer comprise lead frames.
9. A method for assembling a solar cell package, comprising:
providing a third layer, wherein, the third layer comprises a second raised portion;
disposing a second electrically conductive layer on the third layer, wherein the second layer comprises:
a second top surface;
a second bottom surface;
a first raised portion comprising a second ledge extending from the second top surface and defining a second window on an upper surface; and
a second cavity within the first raised portion and aligned with the second window;
disposing a photovoltaic device over the second window and on the second ledge, wherein the photovoltaic device comprises:
a top surface comprising a cathode; and
a bottom surface comprising;
disposing a first insulating layer on the second electrically conductive laver; and
disposing a first layer on the photovoltaic device and on the first insulating layer, wherein the first layer comprises:
a first top surface;
a first bottom surface; and
a first ledge extending from the first top surface and defining a first window;
to provide a solar cell package;
wherein the cathode is electrically interconnected to the first ledge and the anode is electrically interconnected to the second ledge.
10. A photovoltaic system comprising at least one assembly of claim 1 .