Cross Dichroic Prism Solar Array With Three-Band Spectral Separation
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Solution Overview
Problem
Existing multiband solar cell designs face challenges in manufacturing complexity, alignment issues, and high costs due to the use of complex optics and multiple dichroic filters, limiting their widespread application.
Innovation Solution
A cross dichroic prism structure with two dichroic filter films is used to separate solar radiation into three spectral bands, with three inexpensive thin film solar cells deposited directly onto the prism, simplifying manufacturing and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex optics and multiple dichroic filters are used for spectral separation, then spectral band separation capability is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent combines multiple dichroic filter functions into a single integrated dichroic filter element. Instead of using separate filters for different spectral bands, one filter performs multiple wavelength separations simultaneously, reducing the total number of optical components while maintaining spectral separation capability.
Solution Approach 2:
The dichroic filter is designed with multi-functional capability to separate multiple spectral bands (visible and near-infrared) using a single component. This universal filter handles what would traditionally require multiple specialized filters, simplifying the optical system architecture.
2Manufacturing precision
If multiple dichroic filters and complex optics are used, then spectral separation is improved, but ease of manufacture deteriorates
Solution Approach 1:
Multiple filtering functions are merged into one dichroic filter component, reducing the number of assembly steps and alignment operations required during manufacturing. This single-component approach eliminates the need to precisely align multiple separate filters with each other.
Solution Approach 2:
The patent extracts and eliminates unnecessary optical components from the system. By using a single multi-functional dichroic filter instead of multiple filters plus additional optics, the design removes redundant elements that would complicate manufacturing processes.
3Adaptability or versatility
If traditional multi-band solar cell designs are used, then spectral coverage is improved, but cost increases
Solution Approach 1:
The patent combines multiple solar cell functions onto a single substrate that also integrates the dichroic filter. This integration reduces the total component count and eliminates the need for separate mounting, alignment, and connection hardware for multiple cells, thereby reducing overall system cost.
Solution Approach 2:
The solar cell substrate serves multiple functions: it acts as the mechanical support structure, the electrical collection platform, and the mounting base for the dichroic filter. This multi-functional design reduces material requirements and simplifies the bill of materials, lowering cost.
4Ease of manufacture
If solar cells are mounted on separate substrates, then manufacturing flexibility is improved, but alignment precision deteriorates
Solution Approach 1:
The patent merges the solar cell mounting substrate with the dichroic filter substrate into a single integrated structure. This eliminates the need for separate mounting operations and ensures that the solar cell is automatically aligned with the filter's optical axis, achieving high alignment precision without complex assembly procedures.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively separates solar radiation into visible and near-infrared components, maximizing power output while reducing manufacturing complexity and costs, making it suitable for large-scale solar panel arrays.
Implementation Method 1
two dichroic filter films separating the solar radiation into three discrete spectral bands
Implementation Method 2
three inexpensive thin film solar cells are deposited directly onto the prism acting as a substrate
Data Source
AI summary
A unique multiband spectrum solar cell implemented using a cross dichroic prism with the capability to separate incident solar radiation into three visible or infrared spectral components or bands using two dichroic filters is described. Inexpensive thin film solar cells can be deposited directly onto the prism outer surfaces acting as a substrate. The operational spectrum combined by three cells can be designed to cover most of the visible light and infrared (300 nm to 1100 nm) regions providing maximized power output. Manufacture of an elongated (length extended) version is described to increase photovoltaic surface area and create a sub module with space efficient packing into an array supporting a flat panel form factor. Finally, a complete solar panel system is described based upon an array of sub modules combined with power conversion electronics.