Embedded-Cavity Laminate Structures for Solar Cell Light Coupling
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Solution Overview
Problem
Conventional optically functional structures on the surface of transparent substrates are prone to contamination, damage, and inefficient light coupling, leading to low solar cell efficiency due to reflections and miscoupling, especially in solar technology applications.
Innovation Solution
A laminate structure is created by laminating two carrier elements, with one having a surface relief pattern embedded within, forming optically functional cavities that enhance light coupling and trapping, reducing contamination effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If surface relief structures are used to improve light coupling, then light coupling efficiency is improved, but the structures become vulnerable to contamination and damage
Solution Approach 1:
The surface relief pattern is embedded within the laminate structure by laminating the patterned carrier element between other carrier elements. This nesting approach protects the delicate optical pattern from external contamination and mechanical damage while preserving its light coupling function.
Solution Approach 2:
The laminate structure uses thin film carrier elements to encapsulate and protect the embedded surface relief pattern. The flexible yet protective nature of the laminated films shields the optical structures from environmental factors while maintaining optical functionality.
2Productivity
If surface relief structures are used to redirect light, then light coupling efficiency is improved, but the structures are easily contaminated by dust and water
Solution Approach 1:
The surface relief pattern is nested within the laminate structure, placing it between carrier elements that act as protective barriers. This prevents dust and water from directly contacting the optical pattern, eliminating contamination issues while maintaining the light redirecting function.
Solution Approach 2:
The laminate carrier elements serve as intermediary protective layers between the external environment and the surface relief pattern. These intermediaries prevent harmful contaminants from reaching the optical structures while allowing light to pass through and interact with the pattern.
3Productivity
If surface relief structures are used to improve light coupling, then efficiency is improved, but reflections at interfaces cause energy loss
Solution Approach 1:
The laminate structure applies different refractive index materials in specific locations to control light behavior. By carefully selecting materials with appropriate refractive indices for different layers, the structure minimizes reflections at interfaces while maintaining effective light coupling through the embedded surface relief pattern.
Solution Approach 2:
The invention changes the refractive index parameters of the materials used in the laminate structure to optimize light transmission. By selecting materials with specific refractive index values, the structure reduces reflection losses at interfaces while preserving the light coupling enhancement provided by the embedded surface relief pattern.
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 laminate structure improves solar cell efficiency by up to 20-40% by effectively capturing and directing light from a wide range of angles, minimizing reflections, and protecting the embedded patterns from external impacts.
Implementation Method 1
a second carrier element, such as a piece of plastic or glass, provided with at least one surface relief pattern comprising a number of surface relief forms and having at least one predetermined optical function relative to light incident thereon
Implementation Method 2
the first and second carrier elements being laminated together such that the at least one surface relief pattern has been embedded within the established laminate structure and a number of related, optically functional cavities have been formed at the interface of said first and second carrier elements
Data Source
AI summary
An integrated laminate structure (702a, 702b, 801) adapted for application in the context of solar technology, includes a first carrier element (704, 804), such as a piece of plastic or glass, optionally including optically substantially transparent material enabling light transmission therethrough, a second carrier element (702, 802) provided with at least one surface relief pattern (802a) including a number of surface relief forms (708) and having at least one predetermined optical function relative to incident light, the second carrier element including optically substantially transparent material enabling light transmission therethrough, the first and second carrier elements being laminated together such that the at least one surface relief pattern has been embedded within the established laminate structure and a number of related cavities (709) have been formed at the interface of the first and second carrier elements. An applicable method of manufacture is presented.