Novel free-form optical surface design with spiral symmetry

Manufacturing technologies as injection molding or embossing specify their production limits for minimum radii of the vertices or draft angle for demolding, for instance. These restrictions may limit the system optical efficiency or affect the generation of undesired artifacts on the illumination pattern when dealing with optical design. A novel manufacturing concept is presented here, in which the optical surfaces are not obtained from the usual revolution symmetry with respect to a central axis (z axis), but they are calculated as free-form surfaces describing a spiral trajectory around z axis. The main advantage of this new concept lies in the manufacturing process: a molded piece can be easily separated from its mold just by applying a combination of rotational movement around axis z and linear movement along axis z, even for negative draft angles. The general designing procedure will be described in detai

Spiral nonimaging optical designs

Manufacturing technologies as injection molding or embossing specify their production limits for minimum radii of the vertices or draft angle for demolding, for instance. In some demanding nonimaging applications, these restrictions may limit the system optical efficiency or affect the generation of undesired artifacts on the illumination pattern. A novel manufacturing concept is presented here, in which the optical surfaces are not obtained from the usual revolution symmetry with respect to a central axis (z axis), but they are calculated as free-form surfaces describing a spiral trajectory around z axis. The main advantage of this new concept lies in the manufacturing process: a molded piece can be easily separated from its mold just by applying a combination of rotational movement around axis z and linear movement along axis z, even for negative draft angles. Some of these spiral symmetry examples will be shown here, as well as their simulated results

Determination of individual concentrator tolerances from full-array I-V curve measurements

When dealing with CPV manufacturing process, tolerances are critical in order to obtain a low cost massproduction system. Usually the efficiency attained by a whole module array is smaller than the average efficiency of every single module. This downside is due to the well-known mismatch losses introduced by the cell series connection. For this reason, we present a novel mathematical method to calculate photocurrent versus pointing angle curves for the single-cell modules, with the only information of photocurrent versus pointing angle measurements for the whole module array. In this way we can estimate the mismatch losses for a given array just by analyzing its full-array I-V curve. Thus, the great breakthrough about this method lies in no single-cell module measurement is needed. The application of this method allows the measurement of the real tolerances of any CPV system

9-fold Fresnel-Kohler concentrator with Fresnel lens of variable focal point

Non-uniform irradiance patterns over Multi-Junction Cells gives rise to power losses, especially when considering spectral irradiance distributions over different junctions. Thermal effects on Silicone-on-Glass lenses affect spectral irradiance distributions. A new Photovoltaic Concentrator (CPV), formed by nine optical channels, each one with a Köhler configuration, has been designed to overcome these effects at high concentrations for a large acceptance angle. A Fresnel Lens with a Variable Focal Point is proposed to prevent optical crosstalk in multichannel systems. When integrated into the concentrator, improves the acceptance angle. These designs are designed to fulfill the expected requirements of four junction CPV systems

New Fresnel Köhler optical design: 9-fold photovoltaic concentrator

Non-uniform irradiance patterns created by Concentrated Photovoltaics (CPV) concentrators over Multi-Junction Cells (MJC) can originate significant power losses, especially when there are different spectral irradiance distributions over the different MJC junctions. This fact has an increased importance considering the recent advances in 4 and 5 junction cells. This work presents a new CPV optical design, the 9-fold Fresnel Köhler concentrator, prepared to overcome these effects at high concentrations while maintaining a large acceptance angle, paving the way for a future generation of high efficiency CPV systems of 4 and 5 junction cells

9-fold Fresnel-Köhler concentrator for increased uniform irradiance on high concentrations

Non-uniform irradiance patterns created by Concentrated Photovoltaics (CPV) concentrators over Multi-Junction Cells (MJC) can originate significant power losses, especially when there are different spectral irradiance distributions over the different MJC junctions. This fact has an increased importance considering the recent advances in 4 and 5 junction cells. The spectral irradiance distributions are especially affected with thermal effects on Silicone-on-Glass (SoG) CPV systems. This work presents a new CPV optical design, the 9-fold Fresnel Köhler concentrator, prepared to overcome these effects at high concentrations while maintaining a large acceptance angle, paving the way for a future generation of high efficiency CPV systems of 4 and 5 junction cells

High-efficiency Köhler photovoltaic concentrators with external light confinement

Metal grid lines are a vital element in multijunction solar cells in order to take out from the cell the generated photocurrent. Nevertheless all this implies certain shadowing factor and thus certain reflectivity on cells surface that lowers its light absorption. This reflectivity produces a loss in electrical efficiency and thus a loss in global energy production for CPV systems. We present here an optical design for recovering this portion of reflected light, and thus leading to a system efficiency increase. This new design is based on an external confinement cavity, an optical element able to redirect the light reflected by the cell towards its surface again. It has been possible thanks to the recent invention of the advanced Köhler concentrators by LPI, likely to integrate one of these cavities easily. We have proven the excellent performance of these cavities integrated in this kind of CPV modules offering outstanding results: 33.2% module electrical efficiency @Tcell=25ºC and relative efficiency and Isc gains of over 6%

Towards 35% Efficient Concentrator Modules Based On LPI Köhler Concentrators With External Confinement Cavities

Multijunction solar cells present a certain reflectivity on its surface that lowers its light absorption. This reflectivity produces a loss in electrical efficiency and thus a loss in global energy production for CPV systems. We present here an optical design for recovering this portion of reflected light, and thus leading to a system efficiency increase. This new design is based on an external confinement cavity, an optical element able to redirect the light reflected by the cell towards its surface again. We have proven the excellent performance of these cavities integrated in CPV modules offering outstanding results: 33.2% module electrical efficiency @Tcell  =  25 °C and relative efficiency and Isc gains of over 6

Spiral optical designs for nonimaging applications

Manufacturing technologies as injection molding or embossing specify their production limits for minimum radii of the vertices or draft angle for demolding, for instance. In some demanding nonimaging applications, these restrictions may limit the system optical efficiency or affect the generation of undesired artifacts on the illumination pattern. A novel manufacturing concept is presented here, in which the optical surfaces are not obtained from the usual revolution symmetry with respect to a central axis (z axis), but they are calculated as free-form surfaces describing a spiral trajectory around z axis. The main advantage of this new concept lies in the manufacturing process: a molded piece can be easily separated from its mold just by applying a combination of rotational movement around axis z and linear movement along axis z, even for negative draft angles. Some of these spiral symmetry examples will be shown here, as well as their simulated results

Fabrication and tolerances of optics for high concentration photovoltaics

High Concentration Photovoltaics (HCPV) require an optical system with high efficiency, low cost and large tolerance. We describe the particularities of the HCPV applications, which constrain the optics design and the manufacturing techonologies