Radial Coupling Method for Orthogonal Concentration within Planar Micro-Optic Solar Collectors
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1 Radial Coupling Method for Orthogonal Concentration within Planar Micro-Optic Solar Collectors Jason H. Karp, Eric J. Tremblay and Joseph E. Ford Photonics Systems Integration Lab University of California San Diego Jacobs School of Engineering June 8, 2010 PHOTONIC SYSTEMS INTEGRATION LABORATORY UCSD JACOBS SCHOOL OF ENGINEERING Photo: Kevin Walsh, OLR
2 1934 Issue of Popular Science PHOTONIC SYSTEMS INTEGRATION LABORATORY UCSD JACOBS SCHOOL OF ENGINEERING Solar Collection: 80 years of progress Imagers (2-D tracking) Panels (fixed) Troughs (1-D tracking) APS 1 MWe Solar Power Plant Rethink solar concentrator design to leverage large scale manufacturing techniques such as optical lithography and roll-to-roll processing
3 Concentrated Output 4mm Planar Micro-Optic Concentration 1mm Concentrated Output Coupling mirrors Multiple sub-apertures couple to common output Homogeneous output intensity Uniform thickness (roll-to-roll fabrication) Focused Sunlight Decoupling Loss Slab waveguide symmetric prism coupling Reflective prisms tilt light to TIR Couplers occupy <<1% of waveguide surface Subsequent interaction decouples as loss
4 Design Tradeoffs Field Displacement: Sun subtends ±0.25 θ θ d f tanθ d f tanθ f f Short focal length small coupling area Long focal length easier TIR condition Waveguide Thickness: C flux = Slab Length Slab Thickness x Efficiency Length Slab Thickness Length Slab Thickness Thin waveguide high concentration Thick waveguide increased efficiency
5 Optimized Designs Zemax Non-Sequential Model Lens aberrations Polychromatic illumination Material dispersion Coatings and surface reflections Includes single layer MgF 2 AR coating (@545nm) on lens array surface J. H. Karp, E. J. Tremblay and J. E. Ford, Planar micro-optic solar concentrator, Optics Express, Vol. 18, Issue 2, (2010).
6 Fabrication process: Self-alignment Critical Alignment Tolerance Lens focus must overlap with each coupling location <50μm lateral alignment tolerance <0.01 (0.2mrad) rotational alignment UV Exposure Solution: Self-alignment Mold prism structure in UV-curable photopolymer Expose through lens array to define coupling regions Cured regions remain part of the final device Coupling features made by exposure through lenses Low-cost manufacturing process Continuous roll processing on flexible or rigid substrates
7 1 st Generation Proof-of-Concept Lens Array: Fresnel Technologies F/1.1 hexagonal lens array UVT acrylic 203 mm 255 mm Waveguide: Fisher Scientific Microscope slide (75mm x 50mm) BK7 float glass Molding Polymer: MicroChem Corp SU-8 Photoresist Chemical and thermally resistant Prism Mold: Wavefront Technologies 120 symmetric prisms 50μm period, 14.4μm deep
8 1 st Generation System 160μm (On-axis) Optimized 37.5x F/1.14 plano-convex lens array Strong spherical aberration Gaps between elements Predict low efficiency due to lens performance and fill-factor 1 st Gen
9 Fabricated Couplers Al-coated prism facet 75mm Transparent glass slab 50μm 50mm 200μm 20µm Depth
10 1 st Generation System Testing Illuminated prototype Alignment stage Calibrated detector ±0.25 Illumination 37.5x concentration (2 outputs) 44.8% Simulated efficiency 32.4% Measured efficiency ±1.0 angular acceptance Lens Array Waveguide J. H. Karp, E. J. Tremblay and J. E. Ford, Planar micro-optic solar concentrator, Optics Express, Vol. 18, Issue 2, (2010).
11 TWO-DIMENSIONAL CONCENTRATION (ORTHOGONAL CONCENTRATION)
12 Orthogonal Concentration Optical efficiency depends on geometric concentration Long path lengths additional decoupling and absorption losses High concentration systems require long waveguides Radial coupling Orient couplers to direct light towards a limited output region No change in optical path length minimizes efficiency decrease Single output
13 Radial Concentration Performance Lens NA Back Reflector Mirror curvature lies normal to incident rays V-Trough Confines lens array divergence Up to 5x concentration 20% less propagation loss Extra mirror reflection (reduced efficiency at low concentration) V-trough angle (light rejection from multiple reflections)
14 2 nd Generation System 1 st Generation Prototype 2 nd Generation Prototype F/1.1 plano-convex array Spherical aberration Gaps between lenses Coupler deformation 32.4% optical efficiency F/3.01 plano-convex array Near diffraction-limited 100% fill-factor PDMS master mold Porous to SU-8 solvent Consistent molding
15 2 nd Generation Prototype 23μm (On-axis) 37.5x Optimized 2 nd Gen F/3.01 plano-convex lens array 1.0mm lens pitch 39μm coupling regions (±0.25 ) 1 st Gen Comparable decoupling losses No AR coatings
16 2 nd Generation Couplers 1.7mm 1.0mm 1 st Gen Coupler 110μm 2 nd Gen Coupler Well-defined coupling regions Less lens aberration 83% measured aluminum reflectivity 92% expected reflectivity
17 2 nd Generation Prototype Performance Xe arc lamp solar simulator 37.5x concentration (2 outputs) 76.2% Simulated efficiency 65.6% (83% Al-coating) 52.3% Measured efficiency ±0.38 angular acceptance Output Uniformity Video: Lateral alignment / misalignment effect
18 Radial Concentrator Prototype Fresnel Mirror (backside) Approximate radial coupling with 3 segments 2.5x orthogonal concentration 71x concentration (1 output) 54.7% Simulated efficiency 83% Al reflectivity 25.7% Measured efficiency Loss from residual metal Output
19 Efficiency Improvements 1. Increase mirror reflectivity Aluminum alloys, silver, dielectric 2. Improve liftoff process (eliminate unexposed regions) 3. Reflector adhesion edges peel during development Currently using central region of oversized couplers Explore other photopolymers 4. Reduce prism pitch Eliminate sidewall leakage Reflector Adhesion Prism Pitch Losses
20 Summary and Future Directions In Summary: Planar micro-optic concentration Segmented primary aperture with fewer PV cells Reduced optical volume Lithographic fabrication supports large-scale manufacture Roll or batch processing (similar to flat-panel televisions) Orthogonal concentration through radial coupling Increase concentration ratio without additional decoupling loss Future Directions: Integrate prototype with multijunction PV cells Arc-shaped couplers for increased angular acceptance Planar micro-tracking Lateral translation can collect off-axis sunlight
21 This research is supported by: National Science Foundation (NSF), Small Grants for Exploratory Research (SGER) program California Energy Commission (CEC), Energy Innovations Small Grant (EISG) program Thank You
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