Characterization method and analysis of misalignments in micro-concentrator photovoltaic modules.

Micro-scale concentrator photovoltaics (micro-CPV) is an emerging trend for the development of high-efficiency, low-cost photovoltaic systems. The miniaturization of optics and cells offers advantages in terms of performance and enables differentiation in the PV market. However, the sub-millimeter size of the solar cells used, the intrinsic narrow angular tolerance of CPV optical systems (typically around 0.5° and 2°), and the massive number of cells per module lead to very tight mechanical tolerances. Therefore, determining the misalignments between cells and optics is important for quality control inspection of modules. In this paper, we describe a method for characterizing these misalignments based on image acquisition and its subsequent processing and apply it to a micro-CPV module composed of 572 lens-cell units. This method is validated, using a unique experimental technique that takes advantage of the tracking system embedded in the module. The statistical distributions of misalignments are compared for two tracking positions, residuals are determined and shows the consistency of the method. Finally, the impact of misalignment distributions on the IV curve of the module is discussed.

Roll-to-roll nanoimprint lithography of high efficiency Fresnel lenses for micro-concentrator photovoltaics.

Roll-to-roll nanoimprint lithography (R2R-NIL) is an enabling technology for the low-cost mass production of high-quality micro- and nano-sized optical elements. Particularly, the fabrication of Fresnel lenses using R2R-NIL is a promising approach to produce optical arrays for micro-concentrator photovoltaic modules. This work investigates the application of a continuous R2R imprinting process based on ultraviolet curing of transparent photopolymer resins (UV-NIL) to fabricate high-efficiency and low-cost Fresnel lenses. The morphological attributes and the related optical performance of the lenses fabricated using roll-to-roll UV-NIL on flexible PET sheets yielded optical efficiency values up to ∼ 69% at a concentration ratio of 178X, whereas a value of ∼ 77% was obtained for the UV-NIL batch processed on a flat rigid substrate. Further improvement of the optical efficiency has been achieved by adding moth-eye inspired antireflective (AR) features on the side opposite to the Fresnel motifs via a double-sided R2R UV-NIL process. The process developed paves the way for cost-effective mass production of high-efficiency Fresnel lenses for micro-concentrator photovoltaics.

Comparison of achromatic doublet on glass Fresnel lenses for concentrator photovoltaics.

Silicone on glass (SoG) Fresnel lenses are the reference technology in concentrator photovoltaics (CPV) because of their simplicity and low cost. Nevertheless, their performance is strongly limited by chromatic aberration. As an alternative, in order to overcome such limitation, achromatic doublet on glass (ADG) Fresnel lenses were proposed. Such lenses are achromatic cemented doublet specifically designed for CPV applications. In this paper, a novel ADG architecture is presented and its performance analyzed and compared to previous proposals. The results show that most of the intrinsic optical losses are minimized and a superior optical efficiency can be achieved. The novel ADG design provides an achromatic lens for CPV whose efficiency is almost equal to the reference SoG technology and, at the same time, maintains all the advantages provided by the achromatic design such as the higher maximum attainable concentration and the strongly reduced temperature dependency.

Indoor Experimental Assessment of the Efficiency and Irradiance Spot of the Achromatic Doublet on Glass (ADG) Fresnel Lens for Concentrating Photovoltaics.

We present a method to characterize achromatic Fresnel lenses for photovoltaic applications. The achromatic doublet on glass (ADG) Fresnel lens is composed of two materials, a plastic and an elastomer, whose dispersion characteristics (refractive index variation with wavelength) are different. We first designed the lens geometry and then used ray-tracing simulation, based on the Monte Carlo method, to analyze its performance from the point of view of both optical efficiency and the maximum attainable concentration. Afterwards, ADG Fresnel lens prototypes were manufactured using a simple and reliable method. It consists of a prior injection of plastic parts and a consecutive lamination, together with the elastomer and a glass substrate to fabricate the parquet of ADG Fresnel lenses. The accuracy of the manufactured lens profile is examined using an optical microscope while its optical performance is evaluated using a solar simulator for concentrator photovoltaic systems. The simulator is composed of a xenon flash lamp whose emitted light is reflected by a parabolic mirror. The collimated light has a spectral distribution and an angular aperture similar to the real Sun. We were able to assess the optical performance of the ADG Fresnel lenses by taking photographs of the irradiance spot cast by the lens using a charge-coupled device (CCD) camera and measuring the photocurrent generated by several types of multi junction (MJ) solar cells, which have been previously characterized at a solar simulator for concentrator solar cells. These measurements have demonstrated the achromatic behavior of ADG Fresnel lenses and, as a consequence, the suitability of the modelling and manufacturing methods.

Design and modeling of a cost-effective achromatic Fresnel lens for concentrating photovoltaics.

This paper presents a novel Fresnel lens capable of significantly reducing chromatic aberration in solar applications. The optical performance of this achromatic lens has been analyzed through ray-tracing simulations, showing a concentration factor three times higher than that attained by a classic silicone on glass (SOG) Fresnel lens while maintaining the same acceptance angle. This should avoid the need for a secondary optical element, reducing the cost associated with its manufacturing and assembly and increasing the module reliability. The achromatic lens is made of inexpensive plastic and elastomer which allows a highly scalable and cost-competitive manufacturing process similar to the one currently used for the fabrication of SOG Fresnel lenses.