Polymer Composite Encapsulant With Waveguides for Solar Spectral Shifting
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Solution Overview
Problem
Solar cells face a significant mismatch between their spectral response range and the solar radiation spectrum, leading to inefficiencies in energy conversion, particularly in the infrared and ultraviolet regions, which limits their ability to collect light over a wider range of wavelengths.
Innovation Solution
A polymer composite encapsulant with optical structures, such as waveguide arrays made from high-refractive index acrylate monomers and low-refractive index epoxide monomers, and light conversion materials like fluorescent dye-tagged acrylate monomers, which enhance light collection and conversion across a wider spectrum, allowing for more efficient energy capture and transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional solar cell designs are used, then manufacturing simplicity is maintained, but spectral response range is narrow and mismatched with solar radiation spectrum
Solution Approach 1:
The patent introduces an encapsulant layer as an intermediary component between the solar cell and the environment. This encapsulant contains optical structures (waveguides) and light conversion materials that mediate the interaction between incident light and the solar cell, enabling spectral broadening without modifying the cell itself. The encapsulant acts as a separate functional layer that converts UV and IR light into visible wavelengths matching the cell's spectral response.
Solution Approach 2:
The patent segments the light management functions into distinct components within the encapsulant: UV conversion materials for ultraviolet light, waveguide structures for angular light collection, and IR reflection/conversion mechanisms. This segmentation allows each component to be optimized independently for its specific function while working together to broaden the overall spectral response.
2Productivity
If solar cells are designed to capture wider spectral range, then energy conversion efficiency is improved, but manufacturing cost increases
Solution Approach 1:
The encapsulant serves as a cost-effective intermediary that provides spectral broadening functionality without requiring expensive modifications to the solar cell manufacturing process. Standard solar cells can be paired with the encapsulant layer, which contains the light conversion materials and optical structures needed to capture UV, visible, and IR light.
Solution Approach 2:
The patent utilizes parameter changes in the encapsulant materials to achieve spectral broadening. By selecting materials with specific optical properties (UV-absorbing dyes, IR-reflective coatings, waveguide refractive indices), the system transforms the spectral characteristics of incident light to match the solar cell's response range, improving energy conversion without changing the cell's fundamental structure.
3Adaptability or versatility
If solar cells operate at fixed orientation, then structural simplicity is maintained, but light collection angular range is limited
Solution Approach 1:
The patent addresses angular light collection by introducing a third dimension through three-dimensional waveguide structures within the encapsulant. These waveguides are oriented at various angles and depths, creating a three-dimensional optical network that captures light from a wide range of incident angles without requiring the solar cell itself to be reoriented or structurally modified.
Solution Approach 2:
The waveguide structure is segmented into multiple orientations and layers within the encapsulant. Different waveguide arrays are positioned at various angles to capture light from different directions, with each segment optimized for specific angular ranges. This segmented approach enables omnidirectional light collection while maintaining a relatively simple overall encapsulant structure.
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 polymer composite encapsulant increases the total solar energy flux converted by solar cells, enhances current density, and extends the operational time of solar installations by enabling omnidirectional light reception, thereby improving energy generation efficiency and versatility.
Implementation Method 1
each waveguide in the at least one first waveguide array is commonly oriented at a first angle relative to a normal of a surface of the film... formed by a core of a high-refractive index acrylate monomer and a cladding of a low refractive index epoxide monomer
Implementation Method 2
at least one light conversion material comprising a fluorescent dye-tagged acrylate monomer disposed in the core of each waveguide
Data Source
AI summary
A polymer composite for use as a solar cell encapsulant is defined by a thin film having a first side and an opposing second side and at least one optical structure formed in the film. The least one optical structure includes one or more waveguide formed by a core of a high-refractive index polymer, such as an acrylate and a cladding of a low refractive index polymer, such as a silicone. In a preferred embodiment, two intersecting waveguide arrays are defined, each having waveguides disposed at equal and opposite angles in relation to a normal of a surface of the film. The polymer composite further includes at least one light conversion material that is capable of upconverting and/or downconverting UV and/or IR portions of light entering the film into visible light.