Abstract:
A replaceable solar bulb assembly generates electrical energy that includes a photo voltaic cell for converting solar energy into electrical energy. A housing includes at least one reflector for focusing the solar energy on the photo voltaic cell. A connector removably and mechanically connects the housing to a solar receiver array and electrically connects the photo voltaic cell to the solar receiver array.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims benefit of U.S. Provisional Application No. 61/478,600, filed Apr. 25, 2011, and entitled SYSTEM OF REPLACEABLE BULBS OF CONCENTRATOR PHOTO-VOLTAIC (CPV) SOLAR CELL(S) THAT ARE MOUNTED INSIDE A HERMETICALLY SEALED CASE EQUIPPED WITH A SOLAR ENERGY AMPLIFICATION MECHANISM SUCH AS A FRESNEL LENS OR PARABOLIC MIRROR TO MAGNIFY THE SUN&#39;S RAYS ONTO THE CELL(S) WHICH GENERATES ELECTRICITY THAT IS EXTRACTED VIA BUILT-IN CONNECTORS THAT EXTENDS OUT OF THE BULB, the specification of which is incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     The present invention relates to photovoltaic solar arrays, and more particularly, to replaceable solar bulb assemblies that may be removed and replaced from photovoltaic solar arrays when the solar bulb assembly fails without completely replacing the array. 
     BACKGROUND 
     An array of concentrator photovoltaic (CPV) solar receiver arrays includes a plurality of receiver assemblies arranged in an X by Y array for receiving the Sun&#39;s energy and converting it into electricity. Within current designs, when any particular CPV receiver assembly becomes defective, there is no way to replace the individual receiver assembly. Thus, the only options for solving the problem of a defective assembly are leaving the defective assembly within the array such that the overall electrical energy generated by the array is reduced by the amount of the one receiver, or alternatively, the entire array would have to be replaced. This is due to the fact that current designs for CPV solar energy receivers do not allow for the ready replacement of defective receivers within an array on an individual receiver assembly basis. Thus, there is a need for a design of a CPV solar bulb assembly that enables the assemblies within an array to be individually replaced when the assemblies become defective and cease to function. 
     SUMMARY 
     The present invention as disclosed and described herein, comprises, in one aspect thereof, a replaceable solar bulb assembly for generating electrical energy that includes a photo voltaic cell for converting solar energy into electrical energy. A housing includes at least one reflector for focusing the solar energy on the photo voltaic cell. A connector removably and mechanically connects the housing to a solar receiver array and electrically connects the photo voltaic cell to the solar receiver array. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a more complete understanding, reference is now made to the following description taken in conjunction with the accompanying Drawings in which: 
         FIG. 1  is an illustration of an array of concentrator photovoltaic (CPV) solar bulb assemblies; 
         FIG. 2  is an illustration of a CPV solar bulb assembly; 
         FIG. 3   a  is a cutaway exploded view of a CPV solar bulb assembly; 
         FIG. 3   b  illustrates the components for mechanically and electrically connecting a subassembly with a block connector; 
         FIG. 3   c  illustrates the spring contact of the electrical block; 
         FIG. 3   d  illustrates the electrical connector of a subassembly inserted within the spring contacts of the connector block; 
         FIG. 4  illustrates the sealing edge for the housing of the CPV solar bulb assembly; 
         FIG. 5  illustrates the manner in which the CPV solar bulb assembly may interconnect with a docking mechanism upon an array support structure; 
         FIG. 6  is a side view of a CPV solar bulb assembly and the support rails for connecting the bulb assembly to a solar receiver array; 
         FIG. 7  illustrates a CPV solar bulb assembly inserted within a docking station of a solar receiver array; 
         FIG. 8  illustrates an alternative embodiment of a CPV solar bulb assembly; and 
         FIG. 9  is a cutaway view of the CPV solar bulb assembly of  FIG. 8 . 
     
    
    
     DETAILED DESCRIPTION 
     Referring now to the drawings, wherein like reference numbers are used herein to designate like elements throughout, the various views and embodiments of a replaceable solar bulb assembly for use with a solar receiver array are illustrated and described, and other possible embodiments are described. The figures are not necessarily drawn to scale, and in some instances the drawings have been exaggerated and/or simplified in places for illustrative purposes only. One of ordinary skill in the art will appreciate the many possible applications and variations based on the following examples of possible embodiments. 
     Referring now the drawings, and more particularly to  FIG. 1 , there is illustrated an example of a five by five grid array of CPV solar bulb assemblies  102  mounted upon associated support rails  104  of the array assembly. The array assembly can consist of any number of CPV solar bulb assemblies wherein the support rails  104  may be any desired length to add any desired number of CPV solar bulb assemblies  102 , and multiple support rails  104  can be stacked with each other to provide any desired number of rows or columns. While the present figure illustrates an X by Y array in a single plane, other configurations by be used with the replaceable bulb assemblies. Other possible configurations include arrays occurring in multiple planes or arrays comprising randomly placed bulbs that are synchronized to point at the same direction of the sun rather than symmetrical X by Y arrays. As discussed previously, in prior embodiments, when one of the CPV solar bulb assemblies ceases to function, the only solution for repairing the defective assembly has been to replace the entire array or merely ignore the defective assembly and have a solar receiver array that generates less than the optimal amount of electrical energy. 
     Referring now to  FIG. 2 , there is illustrated one embodiment of a CPV solar bulb assembly. While the present implementation illustrates a square CPV solar bulb assembly, it should be realized that the assembly may be of any shape including circular, oval, rectangular, octagonal, etc., depending on the design needs and requirements of the solar array that is being designed. The CPV solar bulb assembly includes a primary reflector housing  202  that reflects the Sun from the interior surface  204  to a secondary reflector  206 . The secondary reflector  206  concentrates the solar energy onto a concentrator photovoltaic cell within a sub-mount assembly  208 . The sub-mount assembly  208  holds the photovoltaic cell (not shown) and provides a manner for mechanically and electrically connecting the CPV solar bulb assembly to the solar receiver array such as that illustrated in  FIG. 1 . The connection enables the assembly  208  to be easily removed and replaced in the array. 
     The secondary reflector  206  is supported within a transparent cover covering the open surface of the primary reflector housing  202 . This maintains the secondary reflector  206  in a position to receive solar energy from the primary reflector surface  204  and concentrate it on the photovoltaic cell within the sub-mount assembly  208 . The transparent cover additionally protects the interior reflector surface  204  of the primary reflector housing  202  from environmental and other external elements. The sub-mount assembly  208  consisting of the CPV cell (not shown) and a substrate that provides for mechanical support of the CPV cell as well as electrical connection to the CPV cells. The sub-mount assembly  208  also includes a heat sink for dissipating heat from the bulb assembly. Other configurations for the sub-mount assemblies  208  are possible, which may comprise other methods of heat dissipation from the cells other than a passive heat sink as shown in the following description. 
     Referring now to  FIG. 3   a , there is illustrated a cutaway, exploded view of a CPV solar bulb assembly. The primary reflector housing  202  includes the interior reflective surface  204  that receives sunlight and reflects it upward to a secondary reflector  206 . The primary reflector housing  202  may be made of numerous materials such as aluminum or even formed composites. The secondary reflector  206  receives the reflected sunlight from the primary reflector  204  and reflects it down to a hole  302  beneath which the concentrator photovoltaic cell lies for receiving the solar energy. The secondary reflector  206  is suspended within a transparent cover  304  that supports secondary reflector  206  over the hole  302  and protects the interior of reflective surface  204  of the primary reflector housing  202  from weather and other external elements. Other structures for supporting the secondary reflector  206  may also be used. 
     Referring now more particularly to  FIG. 4 , there is illustrated the support ledge and built-in channel of the primary reflector housing  202  for receiving an edge of the transparent cover  304  for providing a seal between the transparent cover and the primary reflector housing  202 . The support ledge consists of a horizontal portion  306  on which the bottom edge of the transparent cover  304  rests. A protrusion within the bottom edge of the transparent cover rests within a channel  308  defined on the surface of the horizontal ledge  306 . The protrusion of the transparent cover  304  rests within the channel  306  and provides a seal between the interior of the primary reflector housing  202  and the external environment. A vertical ledge  310  rests on a side edge of the transparent cover  304  to securely hold the transparent cover  304  within the primary reflector housing  202 . 
     The base wall  312  provides for thermal interconnection between the subassembly  208  and the primary reflector housing  202 . The subassembly  208  consists of a mounting plate  314  that provides support for the CPV photovoltaic cell  316 . Connected to the bottom of the base plate  314  is the heat sink  318 . The base plate  314  can also be formed as a part of the heat sink  318 . The heat sink  318  dissipates heat that is generated by the solar energy falling on the main reflector assembly  202  and also directly on the solar cell  316  which directly heats up the base plate  314  and heat sink  318 . The heat sink  318  may alternatively be formed as part of the housing  202 . A pair of metal connectors  318  connect the subassembly  208  to the primary reflector housing  202 . Additionally, these metal connectors  320  will conduct electricity from the solar cell  316  to electrical contacts housed in connector blocks  510 . 
     Referring now to  FIGS. 3   b - 3   d , there are more fully illustrated the manner in which the metal connector  318  will engage the connector block  510  and secure the subassembly  208  to the rest of the solar array both mechanically and electrically.  FIG. 3   b  illustrates the subassembly  208  prior to insertion of the metal connector  318  into the slot  512  of the connector block  510 . As can be seen, the metal connector  318  includes a rounded head  360  that will fit within the slot  512  and engage a pair of spring contacts  562 . The spring contacts  562  are electrically connected to an output line  564  that provides electrical power provided from the subassembly  208  to the cables  514  of the solar array. 
     Referring now also to  FIG. 3   c , there is illustrated a view of the spring contacts  562 . The spring contacts  562  comprise an electrically conductive material, in a preferred embodiment, some type of metal, in a circular configuration having a slot  364  defined therein. The spring contact  562  material is flexible enabling the spring to flex outward when the rounded head  360  of the metal connector  318  is forced into contact therewith. When the rounded head  360  contacts the spring contact  562 , the rounded head will force the contact outward in the direction indicated generally by arrows  366 . After the rounded head  360  has passed by, the spring contact  562  will snap back into place as indicated generally by the arrows  368  to provide a secure connection to the metal connector  318 . Electrical energy provided by the subassembly  208  will flow out of the electrical connector  318  to the spring contacts  562  and out of the electrical output line  564 . The spring contact  562  provides both mechanical interconnection between the subassembly  208  and the connector block  510  while further providing for the ability to transmit electrical energy between the subassembly  208  and connector block  510 . The fully inserted connection between the electrical connector  318  and the spring contacts  562  of the connector block is more fully illustrated in  FIG. 3   d.    
     Referring now to  FIGS. 5 and 6 , there is illustrated the solar bulb assembly  502  and support rail  504 .  FIG. 5  illustrates a CPV solar bulb assembly  502  that has not yet been connected to the array structure. The solar receiver array  504  includes a support rail  504  for holding the solar bulb assemblies  502  and aligning them within an array. A pair of connector blocks  510  are positioned to receive the heat sink between them, and the metal connectors  320  are inserted within a slot  512  within the connector blocks  510 . The connector blocks  510  are placed apart a predetermined distance in order to receive the heat sink  318  of the CPV solar bulb assembly  502 . The connector blocks  510  provide for electrical power transmission and structural support of the CPV solar bulb assembly  502 . The connector blocks  510  are electrically connected to cables  514  within the rail  504 . 
     The illustration in  FIG. 6  shows how the metal connector  320  may be inserted down in the slot  512  within the connector  510 .  FIG. 6  also more fully illustrates the power transmission cables  514 . Each of these cables  514  are connected to receive the electrical power generated by the concentrator photovoltaic circuit within the CPV solar bulb assembly  502 . This is more fully illustrated in  FIG. 7 , which shows the CPV solar bulb assembly  502  connected to the support rail  504 . The metal connector  320  is inserted into the slot  602  to mechanically and electrically connect the CPV solar bulb assembly to the connectors  510 . The heat sink  318  is inserted between each of the connectors  510  to further provide structural support therefor. The CPV solar bulb assembly is seated flush with the rail  504  and electrically connected to the connectors  510 , which transmit electricity down the rail  504  to join with other modules within the array. 
     Referring now to  FIGS. 8 and 9 , there are illustrated an alternative embodiment of the CPV solar bulb assembly wherein the primary reflector housing  802  includes a surrounding wall  804  integrally formed with an edge of a primary reflector  806 . The top edge of the surrounding wall  804  defines a ledge  808  for supporting a transparent cover  810  within the center of the transparent cover  810  is the secondary reflector  812 . The transparent cover  810  environmentally seals the interior of the solar bulb assembly. 
     The housing  802  may include a built-in or attached heat sink  814 . The heat sink  814  enables the removal of heat energy caused from the sun radiating upon the solar cell  816  mounted on a support plate  818 . The quick connect bolts  820  connect to the bottom of the housing  802  providing electrical contacts between the CPV cell  816  and the energy cable upon the various support rods discussed previously. The bolts  820  electrically connect the solar cell to electrical sockets providing for energy transport. 
     Using the configuration described hereinabove, the design enables users to provide an assembly of variable size arrays of CPV solar bulb assemblies by merely plugging in the desired number of CPV solar bulb assemblies to achieve a desired level of power generation. The Arrays may comprise a variety of configurations including a single plane X by Y array or arrays occurring in multiple planes. The arrays may also comprise randomly placed bulbs that are synchronized to point at the same direction of the sun rather than symmetrical X by Y arrays. Additionally, this system provides for easy maintenance of the array of solar bulb assemblies by simply unplugging a defective bulb and replacing it with a good bulb. By standardizing the bulb design, volume runs can be made, which reduces the individual costs of the bulbs which can be easily shipped and stored for future use. Utilizing the bulb design reduces the waste resulting from replacing a complete array of CPV cell solar bulb systems which become inoperative due to a single non-performing CPV cell. Using these bulbs, only the defective bulb needs to be replaced while the frame socket need not be removed. 
     It will be appreciated by those skilled in the art having the benefit of this disclosure that this replaceable solar bulb assembly for use with a solar receiver array provides for better maintenance of the array when the bulb assembly becomes defective. It should be understood that the drawings and detailed description herein are to be regarded in an illustrative rather than a restrictive manner, and are not intended to be limiting to the particular forms and examples disclosed. On the contrary, included are any further modifications, changes, rearrangements, substitutions, alternatives, design choices, and embodiments apparent to those of ordinary skill in the art, without departing from the spirit and scope hereof, as defined by the following claims. Thus, it is intended that the following claims be interpreted to embrace all such further modifications, changes, rearrangements, substitutions, alternatives, design choices, and embodiments.