Planar Solar Concentrator With Deformable Optical Coupling
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Solution Overview
Problem
Conventional planar solar energy concentrators require high precision in fabrication and alignment of layers to achieve efficient light transmission, making them economically unfeasible due to the need for precise manufacturing and assembly processes.
Innovation Solution
The use of a deformable optical coupling element that forms optical apertures when the light insertion and guide layers are brought together during assembly, allowing for reduced precision in manufacturing and alignment while maintaining high light transmission efficiency by directly optically coupling the layers without an air gap.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional planar solar energy concentrators use separate light insertion layer and light guide layer with air gap, then light transmission can occur, but manufacturing precision and alignment precision requirements become excessively high
Solution Approach 1:
The patent introduces an optical coupling layer as an intermediary between the light insertion layer and light guide layer. This coupling layer eliminates the need for precise air gap maintenance while ensuring effective optical communication. The optical coupling layer acts as a mediator that tolerates manufacturing variations and alignment imperfections, thereby reducing precision requirements without compromising light transmission efficiency.
Solution Approach 2:
The patent changes the physical state and optical parameters of the interface between layers by replacing the air gap with an optical coupling layer having specific refractive index properties. This parameter change allows for greater tolerance in layer positioning and reduces sensitivity to alignment precision, directly addressing the contradiction between maintaining light transmission efficiency and reducing manufacturing precision requirements.
2Reliability
If high precision manufacturing and assembly processes are used for planar solar energy concentrators, then light transmission efficiency is maintained, but production cost increases significantly
Solution Approach 1:
The optical coupling layer serves as a mediator that simplifies the manufacturing process by eliminating the need for precision alignment fixtures and complex assembly procedures. Its presence allows for standard manufacturing tolerances to be used, thereby reducing manufacturing complexity and cost while maintaining light transmission efficiency.
Solution Approach 2:
The optical coupling layer provides beforehand cushioning against alignment errors and manufacturing variations. By designing the system with this compensating element in place, the patent anticipates and mitigates potential alignment issues before they affect performance, thereby reducing the need for expensive precision manufacturing processes.
3Reliability
If air gap is maintained between light insertion layer and light guide layer, then optical communication can occur, but manufacturing tolerance becomes extremely tight
Solution Approach 1:
The optical coupling layer replaces the air gap intermediary with a material intermediary that is more tolerant of thickness variations. This coupling layer maintains optical communication between layers while accommodating larger variations in gap distance, thereby relaxing manufacturing precision requirements for gap control.
Solution Approach 2:
The patent uses a composite structure where the optical coupling layer is made of material with specific optical properties (refractive index) that enable effective light transmission across the interface. This composite approach allows the system to function with greater manufacturing tolerance compared to a simple air gap configuration.
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
This approach reduces the manufacturing and assembly precision requirements, maintaining high light recovery efficiency and making the solar concentrators more economically viable by allowing for 'play' between layers without affecting optical communication.
Implementation Method 1
formed by interfaces between at least one of the light insertion layer and the light guide layer and at least one deformed optical coupling element
Implementation Method 2
Each of the optical redirecting elements is for receiving light and redirecting received light towards the optical exit associated with that one of the optical redirecting elements
Implementation Method 3
The first surface and the second surface of the light guide layer are structured and arranged with one respect to the other such that light entering the light guide layer is guided through the light guide layer to at one least one light guide layer optical output surface via a series of reflections
Data Source
AI summary
A solar concentrator, comprising: a substantially planar light insertion layer being made of light-transmissive material and including: an optical entry surface, an array of optical redirecting elements, and an array of optical exits being, each of the optical redirecting elements receiving and redirecting light towards an optical exit; a substantially planar light guide layer being made of light-transmissive material and including: a first surface for receiving light exiting the light insertion layer, a second surface opposite the first surface, the first and second surfaces being structured and arranged with one respect to the other such that light entering the light guide layer is guided to at least one optical output surface via a series of reflections; and an array of optical apertures optically interconnecting the light insertion layer and the light guide layer formed by at least one deformed optical coupling element. A method of manufacture thereof is also disclosed.