| Summary: | 碩士 === 國立高雄應用科技大學 === 模具工程系 === 100 === In view of the gradual depletion of the Earth's energy, a lot of photovoltaic module(PV module) import life supply. however, the conversion efficiency of silicon PV module of about 14% ~ 16%, to reduce the PV module and system manufacturing cost, promote application, enhance the efficiency of the conversion is priority. Currently many research methods for enhancing the PV module efficiency, which use lens focus characteristic, to concentrate the sunlight to the PV module, in order to enhance the conversion efficiency, there is a significant benefit.
In this study, use optical software aided design micro-lens and LIGA like process manufacture micro-lens mold with PV module encapsulation transfer printing and measure power. By the micro-lens array (MLA),the fill factor、diameter、alignment angle and other parameters, research PV module power. Optical software simulation the micro-lens focal length of 400μm ~ 440μm, the diameter of 100μm、150μm、200μm and the fill factor of 40%、50%、60%, computation the power of PV module on different alignment angle of 0° ~ 75°, use LIGA like process manufacture micro-lens array mold with the electroforming successfully to get high fill factor micro-lens array nickel mold. When laminated encapsulation, the nickel mold put the PV module surface, is the processing Surface material DuPont ETFE film bottom base, obtained surface of the PV module with micro-lens array by hot pressing transfer, finally, using the cell test to measure PV module power.
The simulation results showed: when the PV module on the alignment angle 0 ° micro-lens focal length 420μm, increase benefit up to 6.22%. When the micro-lens of diameter are 100μm、150μm、200μm, gap are 25μm、50μm、75μm and the equal gap, the fill factor increase due to the with the diameter increased. Therefore, micro-lens diameter is 200μm, gap 25μm, on the alignment angle of 0°, the maximum increase benefit 1.6%；when the micro-lens of diameter are 100μm、150μm、200μm, fill factor are 40%、50%、60% and the fill factor, the micro-lens diameter is 100μm, fill factor 60%, on the alignment angle of 0°, the maximum increase benefit 1.31%, mainly because of the micro-lens height is small, with the light of contact angle is also small, increase the antireflection, can reduce the direct reflection.
The experimental results showed: in this study, the development of the MLA DuPont ETFE, the incident sunlight of the alignment angle from 0° to 60°, micro-lens can focus light, the light is refracted to small incident angle to the solar cell, increasing the radiation intensity on the solar and can reduce direct reflection of sunlight, increase twice refract opportunity. Micro-lens diameter is 200μm, center distance 250μm, fill factor 58%, better than the micro-lens diameter is 150μm, center distance 200μm, fill factor 51%, the fill factor of more than 7%, show that, when the higher fill factor of micro-lens in the same area, micro-lens array can provide better power. Compare simulation result with experimental result, the micro-lens diameter is 150μm, center distance 200μm, on the alignment angle of 0°, the benefit are 0.77% and 0.91%, error value is 0.14%；the micro-lens diameter is 150μm, center distance 225μm, on the alignment angle of 0°, the benefit are 0.46% and 0.53%, error value is 0.07%；the micro-lens diameter is 200μm, center distance 250μm, on the alignment angle of 0°, the benefit are 1.24% and 1.39%, error value is 0.15%, shows simulation result are reliability of on the alignment angle 0°. If can improve the micro-lens manufacture technology can enhance the experimental result benefit.
The research shows of sun from sunrise to sunset alignment angle 0° ~ 60°, power to increase the maximum gain benefit of 2%, can reduce the direct reflection of the incident light increase refraction and can be used in high latitude places with sunshine time is less, provide a stable output power. This is laminated encapsulation technology of micro-lens array PV module integrated and can cost-down large of number produced.
Keywords: PV module、LIGA like Process、Electroforming、Micro-lens array (MLA)、ETFE
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