Thin Film Optical Element with Arrayed Reflecting Surfaces
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Solution Overview
Problem
Existing sunlight collectors face challenges in achieving high efficiency while maintaining a thin form factor, as they require larger thicknesses for directional light output, making it difficult to construct them as thin films.
Innovation Solution
An optical element with a structure layer featuring a plurality of reflecting surfaces, where the length and array pitch of the surfaces are optimized to satisfy specific relational formulae, allowing for efficient light reflection and output even when the shape deviates from design values, using a method that involves transferring a concave-convex shape to a transfer material and joining light transmissive layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional sunlight collector structures are used to achieve high efficiency in taking in and outputting sunlight, then the efficiency of light collection is improved, but the thickness of the collector increases, making it difficult to construct as a thin film
Solution Approach 1:
The invention transitions from conventional three-dimensional bulky structures to a two-dimensional thin film structure by arranging reflecting surfaces in a planar array pattern. This dimensional reduction allows the collector to maintain high light collection efficiency while achieving a thin profile suitable for window integration and other space-constrained applications.
Solution Approach 2:
The collector is segmented into multiple discrete reflecting surfaces arranged in an array, where each surface independently contributes to light redirection. This segmentation allows the system to achieve high overall efficiency through cumulative effect of multiple small reflective elements rather than requiring a single thick reflective structure.
2Ease of manufacture
If the shape of reflecting surfaces deviates from design values due to manufacturing processes, then manufacturing becomes easier and more cost-effective, but the optical characteristics are adversely affected
Solution Approach 1:
The invention identifies and optimizes critical geometric parameters of the reflecting surfaces (such as pitch, length, and orientation) to create design specifications that are tolerant to manufacturing variations. By carefully selecting these parameters within specific ranges, the system maintains robust optical performance even when actual manufactured dimensions slightly deviate from theoretical design values.
Solution Approach 2:
The design incorporates built-in tolerance margins and redundancy in the reflecting surface array configuration to compensate for expected manufacturing deviations. This preemptive approach ensures that even with normal manufacturing variations, the optical characteristics remain within acceptable performance thresholds.
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 enables efficient light collection and output in a thin form factor, reducing the impact of shape deviations on optical characteristics and enhancing the efficiency of sunlight collection and distribution.
Implementation Method 1
a plurality of reflecting surfaces arrayed in a first region defined by the first surface and the second surface, wherein light incident on one of the first surface and the second surface is reflected by the reflecting surfaces toward the other surface
Data Source
AI summary
An optical element includes a first surface, a second surface positioned to face the first surface, and a plurality of reflecting surfaces arrayed in a first region defined by the first surface and the second surface, wherein the reflecting surfaces have a first length in a first direction vertical to the first surface and are arrayed at a pitch in a second direction perpendicular to the first direction, light incident on one of the first surface and the second surface is reflected by the reflecting surfaces toward the other surface, and predetermined parameters satisfy predetermined relational formulae representing conditions for ensuring total reflection at the reflecting surfaces and for avoiding total reflection at a light emergent surface.