Integrated semiconductor solar cell package
A device containing a solar cell is provided in the form of a stacked package that has a planar arrangement of conductive laminates at or below the surface of a heat sink. The planar alignment allows placement of electrical connections below the surface of the heat sink and reduces the vertical profile of the device, making it easier to be hermetically sealed. In specific embodiments the solar cell substrate is embedded within the heat sink during the manufacturing phase, eliminating the need for a thermally conductive substrate between the solar cell and the heat sink.
1. A solar cell device comprising:
a heat sink having an upper surface, said upper surface having a recessed channel connecting a recessed central region of said upper surface with an edge of said upper surface;
a laminate disposed in said recessed channel, wherein said laminate comprises:
a proximal end disposed toward the central region of the heatsink and a distal end disposed toward the edge;
the proximal end of the laminate defining a center cavity therethrough;
at least one electrically conductive layer; and
at least one electrically non-conductive layer comprising a non-ceramic printed circuit board material;
a thermally conductive insert disposed within and through the center cavity of the laminate, wherein,
the thermally conductive insert comprises a thermally-conductive material metalized on an upper surface and on a lower surface; and
the lower surface is bonded to the recessed central region of the heatsink; and
a solar cell, wherein the solar cell is bonded to the upper surface of the thermally conductive insert and the solar cell is electrically connected to the at least one electrically conductive layer;
wherein the solar cell and an upper surface of the laminate is lower than the upper surface of the heat sink.
2. The device of claim 1 , wherein the at least one electrically non-conductive layer of said laminate comprises temperature resistant printed circuit board material.
3. The device of claim 1 wherein the at least one electrically non-conductive layer comprises a material selected from the group consisting of aluminum nitride, beryllium oxide, graphite, silicon carbide and aluminum silicon carbide.
4. The device of claim 1 wherein the solar cell is hermetically sealed.
5. The device of claim 1 , comprising one or more bypass diodes, wherein the one or more bypass diodes are electrically connected to said solar cell and to said electrically conductive layer.
6. The device of claim 1 , wherein the laminate comprises a metallic conductive layer comprising extended fingers sandwiched between sheets of temperature resistant printed circuit board material.
7. The device of claim 1 , wherein the laminate comprises a tripartite laminate.
8. The device of claim 1 , wherein the non-ceramic printed circuit board material is selected from a glass-reinforced epoxy, polyimide, carbon composite, and fiber-reinforced epoxy resin.
9. The device of claim 1 , wherein the laminate comprises a five-layer sandwich.
10. The device of claim 1 , wherein each of the metallized upper surface and the metallized lower surface is unpatterned.
11. The device of claim 1 , wherein the solar cell comprises an anode is bonded to the metallized upper surface of the insert.
12. The device of claim 1 , wherein the solar cell is electrically connected to proximal finger terminals with wire or ribbon bonds.
13. The device of claim 1 , wherein the insert is electrically connected to proximal finger terminals with wire or ribbon bonds.
14. A solar cell device comprising:
a heat sink comprising an upper surface, a central region, and a plurality of recessed channels extended from the central region to respective corners of the upper surface of the heat sink;
a thermally and electrically conductive laminate disposed within each of the plurality of recessed channels; wherein
each of the thermally and electrically conductive laminates comprises at least one electrically conductive layer, at least one electrically non-conductive layer, and an electrical interconnection terminal; and
the thermally and electrically conductive laminates define a cavity therethrough located at the central region of the heat sink;
a thermally conductive insert disposed within and through the cavity; wherein the thermally conductive insert comprises a metallized top surface and a metallized bottom surface; and
the metallized bottom surface is bonded to the heat sink and a solar cell, wherein
the solar cell is bonded to the metallized top surface of the thermally conductive insert, and the solar cell is bonded to at least one of the electrical interconnection terminals.
15. The device of claim 14 , comprising one or more bypass diodes disposed within the cavity and electrically connected to the solar cell.
16. The device of claim 14 , wherein the thermally conductive insert comprises a material selected from aluminum nitride, beryllium oxide, graphite, silicon carbide, and aluminum silicon carbide.
17. The device of claim 14 , wherein the at least one electrically non-conductive layer of said laminate comprises a temperature resistant printed circuit board material.
18. The device of claim 14 , wherein the solar cell is hermetically sealed.