Method of manufacturing photovoltaic (PV) enhancement films

A method for manufacturing a photovoltaic (PV) enhancement film. The method includes providing an extrusion device with an embossing roller engraved to have a pattern corresponding to a set of absorption enhancement structures. The method includes feeding a web of substantially transparent material, such as an UV-stabilized blend of polycarbonate or acrylic. The method includes rolling the embossing roller against a first side of the web to form the absorption enhancement structures. The absorption enhancement structures each include a light receiving surface that directs at least a portion of light that passes through a second side of the web toward the first side back toward the second side (e.g., the structures may be configured to provide total internal reflection when applied to a PV device). The structures refract incident light to provide an average path length ratio of greater than about 1.10 in the PV device.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates, in general, to methods of manufacturing devices and systems for converting solar energy into electricity such as devices using the photovoltaic effect to convert solar energy directly into electricity, and, more particularly, to a methods of manufacturing a PV device such as a module, array, or panel of solar cells that includes a PV enhancement (or light trapping) layer or film to better trap or capture light or rays from the Sun that are incident on a front or receiving surface of the PV device to achieve enhanced absorption and conversion of the solar energy into electricity. The methods of manufacture are particularly adapted for producing the PV enhancement film that is configured to reduce reflection or loss of incident light when the Sun is normal to the front surface of a solar cell (or to the solar module, array, or panel) and also at oblique angles, thus reducing the need to track the Sun's position with the PV device including the PV enhancement film.

2. Relevant Background

With the growing interest in renewable energy including use of solar power, there is an increasing demand for more efficient solar cells. Solar cells or photovoltaic (PV) cells are devices that convert solar energy into electricity by the photovoltaic effect, and solar cells are widely used in devices ranging from satellites and other applications including portable consumer electronic devices that are remote from a conventional power source. More recently, large solar power

collection systems with arrays of cells or PV modules (or solar panels) are being used to supply power to electrical grids for distribution to consumers. Several concerns are limiting the implementation of solar cells including cost of materials and manufacturing, environmental concerns with materials such as lead, and low efficiency of the cells. As a result, researchers continue to look for ways to lower manufacturing costs and for ways to enhance the efficiencies of solar cells and panels, modules, or arrays that include such cells. For example, existing solar cells, such as those based on a silicon substrate, typically have efficiencies of 10 to 20 percent, and, as a result, even small increases (e.g., of one to several percent) in efficiency may represent large relative gains in being able to convert solar energy into useful electricity (e.g., an increase in efficiency of 1 to 2 percent represents a 5 to 20 percent or higher gain in efficiency for a cell design). Even with these limitations, though, the manufacture and installation of solar cells and PV arrays has expanded dramatically in recent years. Some estimates indicate that PV production has been doubling every two years making it the world's fastest growing energy technology, with about 90 percent of the capacity being grid-tied electrical systems that are ground mounted (e.g., in solar farms) or on building roofs/walls. Concerns with global warming and financial incentives provided by world governments will likely only increase the demand for PV arrays and the demand for more efficient solar cells.

Solar cells or photovoltaics (or PV devices) convert sunlight directly into electricity and generally are made of semiconducting materials similar to those used in computer chips. When sunlight is absorbed by these materials, the solar energy frees electrons loose from their atoms, which allows the electrons to flow through the material to produce electricity. The process of converting light (i.e., photons) to electricity is called the photovoltaic (PV) effect. In practice, solar cells are typically combined into modules that hold numerous cells (e.g., up to 40 or more cells), and a set of these modules (e.g., up to 10 or more) are mounted in PV arrays or solar panels that can measure up to several meters or more per side, with each cell typically only being up to 100 to 150 square centimeters in size. These flat-plate PV arrays are mounted at a fixed angle facing the Sun (e.g., south) or they may be mounted on a tracking device that follows the position of the Sun to allow them to better capture the Sun's light throughout the day. Solar cells may be formed using thin film technologies to use layers of semiconductor materials that are only a few micrometers thick.

The performance of a solar cell is measured in terms of its efficiency at turning sunlight into electricity. Only sunlight of certain energies will work efficiently to create electricity and much of this desirable energy sunlight may be reflected from the surfaces of the solar cell or absorbed by its materials without creating electricity. Due to these and other areas for loss of sunlight, a typical solar cell may have an efficiency ranging from about 5 to 20 percent, with some highly efficient solar cells claiming efficiencies of up to 22 percent or higher. For example, an energy conversion efficiency of 22 percent was announced in 2007 as being a world record event for a practical-sized (e.g., about 100 cm2), crystalline silicon-type solar cell (e.g., an HIT solar cell composed of a single thin crystalline silicon wafer surrounded by ultra-thin amorphous silicon layers). Low efficiencies mean that larger arrays are required to provide a particular amount of electricity, which increases the material and manufacturing costs. As a result, improving solar cell efficiencies while holding down the cost per cell continues to be an important goal of the solar power industry.

Even when a PV array is positioned normal to the Sun's rays, sunlight is reflected or lost to a typical solar cell, with estimates at 5 to 33 percent or more of the light being spectrally reflected and lost. In some cases, the solar cells may be protected from the environment with a glass sheet or with transparent plastic packaging. Significant efforts have been made in the solar power industry to boost efficiency by reducing reflection when the sunlight is incident at a normal angle (or when the angle of incidence is at or near zero degrees) on the PV array. Typical solutions have called for application of an antireflection coating of a material such as SiNxlayer or the like on the cell and/or upon the protective glass/plastic layer to minimize the reflection of light from this protective layer. The AR coating provides a layer or layers of material with a desirable refractive index and thickness (e.g., a quarter wavelength) to lessen reflection of sunlight at the coated surface (e.g., the planar surface of the sheet of protective glass). In some embodiments, the AR coating may be a metal fluoride combined with silica (e.g., a flouropolymer), a zinc or other metal oxide (or other transparent conductive oxide), or other material layer. Recently, coatings formed of a single-layer of porous silicon oxide have been applied to a protective glass layer to decrease glass reflection by about 3 percent at noon and by about 6 percent in mornings and evenings (e.g., when the sunlight strikes the solar cell at an oblique or non-zero incident angle). Additionally, other AR coatings are being developed including textured-dielectric coatings and multi-layered, nanostructured coatings (e.g., seven layers of silicon dioxide and titanium dioxide nanorods). While providing some improvements in light capture and efficiency of solar cells, existing AR coatings generally are most useful in controlling reflection of sunlight when the sunlight is striking the PV array at normal (e.g., near noon for many arrays) and do little to limit other types of reflection or bounce back losses.

As discussed above, the largest problem with the rapidly developing technology of photovoltaics revolves around cost-versus-efficiency. Whether traditional silicon materials are used or newer cadmium telluride or copper photovoltaic constructions are used, efficiencies are still a significant limitation on solar cell use and adoption by consumers and the power industry. While multiple-layered more expensive PV cells that are designed for concentrator systems or to absorb a wider variety of wavelengths (including the longer wave lengths) are significantly more efficient, the more elaborate and expensive multi-layer PV materials also result in increased ray loss at angles other than nearly perfect toward the Sun in both axis. This additional loss is caused by increased ray deflection as a result of cosine fall off as well as the narrow acceptance angles required by the complexity of the PV structures as they attempt to use more of the available wave lengths.

Losses in absorption into PV materials are caused by several factors. One of the factors is normal “cosine fall off” or the lack of absorption due to the incoming angle of the sunlight and the relationship of the incoming rays to the structures in the PV materials. For example, a typical solar cell will have an upper or front surface that is not perfectly planar but is instead textured or rough. This results in many of the rays simply being deflected off of the surface of the PV materials and not being absorbed. However, this phenomenon also happens even when sunlight or rays are directed directly into the PV materials at zero degrees or at a perfect angle into the PV material. Part of the reason for the deflection of the rays is that the structures within the PV materials are not flat and are for the most part three-dimensional. Incoming rays, even when perfectly aimed, are bouncing off these structures (e.g., are reflected) and are never absorbed by the solar cell.

Hence, there remains a need for improved solar cell devices/products such as PV arrays that better control reflection and/or increase the amount of incident sunlight that is absorbed by the solar cells. Preferably, the improved solar cells would have improved energy conversion efficiencies with or without tracking of the Sun's position, and the solar cells and PV arrays of solar cells would not be significantly more expensive to manufacture or require redesigns/modification of the underlying solar cell configuration or makeup.

SUMMARY OF THE INVENTION

The present invention addresses the above problems by providing photovoltaic (PV) enhancement films for use with solar panels/arrays and solar cells (or other PV devices) to increase the efficiency of the PV materials in absorbing available solar energy. Specifically, the PV enhancement films are designed to increase the efficiency of the PV materials (or PV device) by modifying or enhancing the optical path length of received or incident light through the PV material for better absorption. The PV enhancement films may combine this function of increasing (or even optimizing) path lengths with an ability to capture or trap light reflected from light-receiving surfaces of solar cells that normally would be lost and direct this reflected light back onto the light-receiving surfaces (often at a different incidence angle) for second or additional chances for absorption and conversion into electricity. The trapping or redirection of the light is achieved through the use of total internal reflection (TIR), and the PV enhancement films act to pass most incident light onto the light-receiving surface (without significant focusing) and then trap a significant portion of reflected light back to the light-receiving surface.

The PV enhancement films may be formed of a plastic, glass, ceramic, or other substantially transparent material (e.g., highly light transmissive material such as an energy-cured polymer) and include a thin substrate upon which a plurality of elements or structures are formed (or provided). These elements may be termed TIR structures or elements while also functioning to provide optical path length modification, and, hence, these structures or elements are also labeled as absorption enhancement structures or elements herein (i.e., wherever the term TIR structure is used in this description the term absorption enhancement structure may be substituted as a structure designed to provide TIR also will typically provide at least some amount of desired path length lengthening). The TIR or absorption enhancement structures may be chosen to provide a combined functionality: (a) to optimize or increase the optical path length of light passing through the PV materials and also (b) to provide at least some capture of reflected light such as via TIR or the like. In this manner, the absorption enhancement structures increase absorption for light passed to the PV material while also capturing a portion of the light that may be lost due to reflection to increase absorption by providing second, third, or more chances to absorb light reflected from the PV device layers (such as from the light receiving surface of the PV materials such as a thin film of PV material).

Each of the absorption enhancement elements is designed to receive and transmit the received light with a modified direction/angle to modify path length and then to direct reflected light from the solar cell back to its light-receiving surface for possible absorption. For example, the absorption enhancement elements are elongated structures that are provided with a sawtooth pattern on a side of the substrate with the triangular cross section absorption enhancement elements each providing two facets to alter the path of incident light and to trap reflected light via TIR. In other cases, the absorption enhancement elements are three-dimensional (3D) structures on the surface of the substrate that each act to alter the path of incident light to provide an enhanced optical path length through the PV materials and to also reflect back otherwise lost sunlight, e.g., a plurality of hemispherical/dome shaped bodies, full or truncated cone shaped bodies (frustoconical shapes), three-sided or four-sided (or more-sided) pyramids (coming to a true point/apex, to a flat/planar side/facet, to a curved, domed, or hemispherical point, or other termination), and so on. Through modeling with ray tracing computer programs, it is believed likely that the PV enhancement films will provide better optimized optical path lengths of received light and to capture enough reflected light to significantly increase efficiencies of solar cells, solar arrays, and the like. For example, modeling indicates that use of some embodiments of the PV enhancement films will increase efficiencies up to 10 percent while other implementations may increase efficiencies up to 35 percent or more (such as in solar arrays with no tracking and with larger reflection losses during off-peak hours and in arrays with very thin films in which increased path lengths improve the amount of absorption).

More particularly, a solar cell assembly is provided for more efficiently capturing solar energy. The assembly includes a PV device including a layer of PV material and a protective top covering the PV material (e.g., a planar glass cover applied with adhesive to the PV material). The assembly further includes a PV enhancement film formed of a substantially transparent material (such as a glass, a plastic, a ceramic, or the like that passes a substantial percentage of received light through), and film is applied to at least a portion of the protective top such as with a substantially transparent adhesive. The PV enhancement film includes a plurality of absorption enhancement structures on the substrate opposite the PV device. Each absorption enhancement structure includes a light receiving surface that refracts incident light striking the PV enhancement film to provide an average path length ratio of greater than about 1:10 in the layer of PV material over a range of incidence angles. The average path length ratio may be determined as an average of path length ratios determined within the range of incidence angles, with each ratio calculated by dividing the length of the path of the refracted incident light through the PV material by the length of the path of the incident light traveling through the PV material in the absence of (or without use of) the PV enhancement film. Such ratios may be determined in some cases based on ray tracings performed at a set of angles within the range of incidence angles taking into account the configuration of the PV enhancement film and its structures and also accounting for effects of the protective top and one or more layers of adhesive.

The range of incidence angles may be selected from the range of plus/minus 80 degrees as measured from an orthogonal plane passing through a light-receiving surface of the PV material. In some cases, though, the range of incidence angles is plus/minus 40 degrees, plus/minus 20 degrees, or even plus/minus 10 degrees to better enhance absorption by the PV material when sun light is at its greatest intensity (and most of the Sun's energy is collected by solar cells or PV devices). The structures may be configured to obtain average path length ratios that are greater than 1.2 in the layer of PV material over the range of incidence angles (or a subrange within the overall range of incidence angles such as from −20 to +20 degrees or the like) while other embodiments provide ratios of 1.5 or better. The structures may also be designed to provide TIR to direct a portion of light reflected from the PV material (or other surfaces) back toward the PV material for possible absorption, and, in this manner, the structures may increase absorption or efficiency of the PV material by either increasing path length or providing TIR or by providing both of these functions in the same or differing portions of the range of incidence angles. The PV material layer may take many forms such as the PV material found in a crystalline silicon solar cell. In other cases, the PV material may be provided by materials/layers found in a thin film solar cell and comprise amorphous silicon, microcrystalline silicon, cadmium telluride, copper indium gallium di-selenide (CIGS), organic PV cell material(s), and the like. The PV enhancement films providing especially good improvement results for amorphous and microcrystalline silicon films but are also expected to be very useful with transparent conducting oxide (TCO) thin films or substrates.

In one embodiment, adjacent ones of the absorption enhancement structures have one of two differing configurations with one configuration chosen to provide better path length enhancement (lengthening in the PV material) in one portion of the range of incidence angles and the other configuration chosen to provide better path length enhancement in a second portion (typically, differing from, but possibly overlapping with, the first portion). In one embodiment, the structures are mixed or alternated in a sawtooth-like pattern with differing height triangular cross sections with similar bases/pitches, e.g., pitches or bases of less than about 15 mils (such as about 13 mils) and heights of less than about 11 mils with one set of structures being less than about 8 mils while the other set is between 8 and 11 mils (e.g, one set of structures may be about 7 mils in height or thickness while the other set is about 10 mils in height). In this manner, each structure acts to provide a more desirable or adequate path length for optimized light capture in the PV material or layer for a portion or subrange of the overall range of incidence angles. For example, a first configuration (e.g., height of about 7 mils) being better at increasing path length when the absolute value of the incidence angle is greater than about 20 degrees while the second configuration may be more effective (as compared to the first configuration) at increasing path length when the absolute value of the incidence angle is less than about 20 degrees.

According to another aspect, one embodiment provides a solar cell assembly for more efficiently capturing solar energy by providing additional chances to absorb reflected sunlight. The assembly includes a solar cell (note in a solar array assembly a plurality of solar cells would be included in the assembly). The solar cell includes a light-receiving surface, and a fraction or percentage of light incident upon the light-receiving surface is reflected over a predefined range of incidence angles (e.g., most light may be absorbed in the range of −10 to 10 degrees, but at more oblique angles of incidence such as greater than 10 degrees and less than −10 degrees, greater and greater portions of the light striking the solar cell may be reflected). Significantly, the solar cell assembly includes a PV enhancement film formed of substantially transparent material (such as a light-transmissive plastic) positioned to cover or abut at least a portion of the light-receiving surface (and, more typically, to cover most or all of the light-receiving surface). The PV enhancement film includes a substrate positioned proximate to or abutting (except for an optional adhesive layer affixing the film to the solar cell) the light-receiving surface. The film also includes a plurality of total internal reflection (TIR) elements on the substrate opposite the light-receiving surface. Each of the TIR elements is designed to direct at least a portion of the reflected light back toward the light-receiving surface of the solar cell.

The TIR elements transmit the light incident (or most of this received light) to the light-receiving surface (e.g., do not block or focus this light) and also direct the portion of the reflected light back to the light-receiving surface using TIR as the reflected light strikes one or more sides of the TIR elements. Each of the TIR elements may have a linear or elongated body with at least two inward angled sides. For example, the TIR elements may have triangular cross sections (e.g., as viewed on end) with sides angled inward at angles of less than about 60 degrees (e.g., of less than about 45 degrees). The TIR elements may be of like size and shape, or the TIR elements may have differing sizes (and/or shapes) such that alternating ones have differing thicknesses for example (or alternating sets of the TIR elements may be configured differently) to tune the optical effect achieved (i.e., differing TIR elements may provide better TIR trapping effects at differing incidence angles and it may be useful to select two or more of such TIR elements in a single PV enhancement film). In another example, the TIR elements are linear but include three, four, or more facets/sides such as two inward angled sides with an upper planar side positioned therebetween that is parallel to the light-receiving surface (e.g., similar to a cross of a pyramid structure). In other embodiments, the PV enhancement film may include a light receiving and trapping surface that defines the TIR elements, and this surface may have a sinusoidal shape when viewed along an edge of the PV enhancement film (e.g., to provide elongated TIR elements with a sinusoidal sectional shape). In other embodiments, the TIR elements are provided on a surface of the substrate opposite the light-receiving surface and have 3D bodies with a shape selected to provide a desired TIR effect (such as a plurality of pyramids or 3 to 4 or more-sided pyramid shapes protruding from a substrate or sheet, numerous hemispherical shaped bodies or domes, a number of cones or truncated cones, and the like). The PV enhancement film may be relatively thin and the TIR elements small to achieve the TIR trapping effect, and, in one embodiment, the TIR elements each has a base and a height less than about 10 mils in magnitude.

According to other aspects or embodiments, a method is provided for manufacturing a photovoltaic (PV) enhancement film. The method includes providing an extrusion device that includes an embossing roller. The embossing roller typically has a surface that is engraved with a contoured pattern corresponding to a plurality of absorption enhancement structures (e.g., a mirror image of the desired structure pattern that may have been cut using diamonds or similar cutting tool bits as described herein or the like). The method further includes feeding a web of substantially transparent material, such as an UV-stabilized blend of polycarbonate, acrylic, or other polymer (with or without other additives), and the material may be at an extrusion temperature to the extrusion device (such as over ambient up to the range of about 350 to 450° F. or the like). The method further includes rolling or pressing the embossing roller against a first side of the web to form the absorption enhancement structures using the contoured pattern. In this formed web or PV enhancement film, the absorption enhancement structures may each include a light receiving surface that directs at least a portion of light that passes through a second side of the web toward the first side back toward the second side (e.g., the structures may be configured to provide TIR functionality when applied to a PV device).

In some embodiments of the method, the light receiving surface is adapted on the structures such that the structures refract incident light striking the first side to provide an average path length ratio of greater than about 1.10 when the embossed web is applied over a layer of PV material over a range of incidence angles. In such cases, the average path length ratio may be determined as an average of a plurality of path length ratios determined within the range of incidence angles with each of the path length ratios being a path length of the refracted incident light traveling through the PV material after passing through the PV enhancement film compared with a path length of the incident light traveling through the PV material in an absence of the PV enhancement film. Further, in such embodiments, the path length ratios may be determined based on ray tracings performed at a plurality of angles within the range of incidence angles. Additionally, the range of incidence angles may be a range of angles selected from the range of negative 80 degrees to positive 80 degrees as measured from an orthogonal plane passing through a light-receiving surface of the PV material. In other cases, the range of incidence angles may be a range of angles selected from the range of negative 20 degrees to positive 20 degrees as measured from an orthogonal plane passing through a light-receiving surface of the PV material.

In some embodiments of the method, each of the absorption enhancement structures formed by the embossing roller or its engraved surface may include an elongated body including at least two sides angled inward. In these embodiments, each of the absorption enhancement structures may have a triangular cross section when taken along a plane passing orthogonal to a longitudinal axis and wherein the sides are angled inward at angles of less than about 60 degrees. Further, adjacent ones of the absorption enhancement structures may have differing heights as measured from the second side to a peak of the triangular cross section of the absorption enhancement structures. In other cases, though, each of the absorption enhancement structures may include three interconnected sides including two sides angled inward at angles of less than about 60 degrees and an upper planar side disposed between the two angled sides that is substantially parallel to the light-receiving surface. In other embodiments, each of the absorption enhancement structures includes an elongated body including a semi-circular cross section while in other examples each of the absorption enhancement structures has a body with a hemispherical shape with a base supported on the substrate. The engraved pattern of the embossing roller may be such that each of the absorption enhancement structures has a body with a pyramid or a frustoconical shape with a base supported on the substrate. In any of these embodiments of the method, each of the absorption enhancement structures may have a base and a height less than about 10 mils in magnitude.

The method may further include cooling the embossed web, applying an adhesive to the second side, and cutting the embossed web into a plurality of PV enhancement films each with a predefined length and width. Also, in some embodiments of the method, the web material comprises polycarbonate or acrylic. The embossed web may have a thickness of less than about 30 mils, the extrusion temperature may be at least about 300° F., and the embossing roller is chilled to a temperature below ambient such as 30 to 50° F. below ambient or lower to more rapidly “freeze” the web surface with the pattern of structures.

According to another aspect or embodiment, a method is provided for fabricating a photovoltaic apparatus with enhanced energy absorption. The method includes providing a layer of photovoltaic (PV) material that is positioned under a protective layer of substantially transparent material. In use, incident light striking the protective layer over a range of incidence angles has a first average path length through the PV material. The method further includes fabricating a PV enhancement film including extruding a web of plastic through a set of rollers including a chilled embossing roller to form a plurality of absorption enhancement structures on a first side of the plastic web. The method may also include applying a layer of adhesive to the second side of the plastic web, and, then, attaching the plastic web to the protective layer opposite the PV material via the adhesive layer. In a typical example of this method, each of the absorption enhancement structures may include a body shaped so as to transmit light incident upon an outer surface of the body toward the PV material at a differing angle than the incident light striking the protective layer and to direct at least a portion of light reflected from the PV material back toward the PV material using total internal reflection (TIR). In such cases, the light incident upon the body over the range of incidence angles may have a second average path length that is at least about 10 percent greater than the first average path length.

The protective layer may include glass and the PV material may include a silicon-based thin film PV device. In some embodiments, the bodies of the absorption enhancement structures are elongated with triangular cross sectional shapes with two sides defining a light receiving and trapping surface using TIR to direct the portion reflected light back to the light-receiving surface and using refraction to provide the differing angle and an average path length ratio of the second average path length to the first average path length is greater than about 1.2. In the method, the bodies of the absorption enhancement structures may each be pyramid shaped with at least three facets, be hemispherical shaped, or be frustoconical shaped. Further, the bodies may each have a base width and a height of less than about 10 mils.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Generally, the present invention is directed to photovoltaic (PV) enhancement films for use in solar panels, arrays, or modules (or with individual solar cells or other PV device) to improve solar efficiencies. The PV enhancement films are adapted to be applied to existing solar arrays, panels, or modules and/or used with solar cells/PV devices during initial manufacture. The PV enhancement films each include a substrate of plastic, glass, or ceramic (e.g., a substantially transparent material such as a thin polymeric film or the like) with a plurality of structures or elements on one surface that are shaped and sized to provide modify/change the direction of received or incident light to provide a more desirable path length (e.g., to make the path length more optimal for absorption of the Sun's energy by the PV materials of a PV device such as a solar array) and also to provide total internal reflection (TIR) to trap or capture at least a portion of light reflected from the light receiving surfaces of the PV materials or of the PV device (such as from the protective glass layer covering).

Herein, these structures or elements will be interchangeably labeled absorption enhancement structures/elements and TIR structures/elements. In part, this terminology is used because initial investigations were mainly directed toward optimizing TIR to improve the efficiency of PV devices, but experiments and studies (such as computer modeling) showed that selecting a structure shape and size to provide a longer path length (e.g., an “optimal” or “optimized” path length) may be more or at least equally important as capturing reflected or otherwise lost sunlight. To this end, efforts to provide the absorption enhancement structures on the PV enhancement films turned toward providing both TIR and more optimized optical path lengths (such as with a single structure design or a film with two or more structure designs providing differing functionality such as alternating structures in an alternating sawtooth pattern with a first structure providing better TIR and a second structure providing better path length improvements (e.g., maximize length for a particular arrangement of PV enhancement film, protective glass element, adhesive layer(s), and PV material)).

The PV enhancement film may be attached to a solar array such that the absorption enhancement structure-side faces the Sun and the opposite (typically planar) side abuts the light receiving side and/or surfaces of the solar cells in the solar array (e.g., attached with adhesive to PV material of a solar cell, to a protective glass coating or element, to a layer of AR material(s), or the like). The absorption enhancement structures may each be adapted to create TIR directionally toward the photovoltaic structures of the solar cells to enhance performance of the solar array (or individual PV device) by deflecting unabsorbed photons back toward the photovoltaic structures for a second (or additional) chance for absorption and conversion into electricity. Briefly, in this regard, each absorption enhancement structure on the PV enhancement film acts to allow incident sunlight to pass relatively unhindered to the solar cells of the array, and, then, to trap a substantial fraction of the reflected or bounced back light with TIR causing the initially unabsorbed sunlight or rays to be returned at least one more time to the solar cell (with some rays being directed to the solar cell 2 to 5 times or more before they are either absorbed or escape the PV enhancement film and the solar array that includes such a film).

Significantly, each absorption enhancement structure also acts to redirect the light so as to change its path as it passes through the absorption enhancement structure to strike the light receiving surface of the PV material (and as it passes through intervening layers of material such as an adhesive attaching the PV enhancement film to the PV device, a protective element such as a glass layer, one or more layers of AR materials, another adhesive attaching the glass/AR to the PV material or its light receiving surface, and so on). By careful selection of the shape and size of the absorption enhancement structure, the optical path length of the incident light may be matched to the PV material/PV device to enhance or improve the portion or fraction of the received light that is absorbed within the PV device (e.g., “optimize” the path length to increase PV device efficiency typically by maximizing the path length for a range of angles of incidence such as plus or minus 40 degrees, plus or minus 30 degrees, plus or minus 20 degrees or the like).

The shape of the absorption enhancement structure may vary widely to practice the invention with some absorption enhancement structures being linear with a triangular, a polygonal, an arcuate or other cross section while others are non-linear with a variety of shapes such as pyramids (three, four, or more angled sides with/without an apex, e.g., a flat or shaped peak rather than a point), domes, cones, frustoconical shapes, and hexagonal shapes (e.g., textured surfaces with domes or other side-by-side absorption enhancement elements on a surface of a sheet or film of transparent material). The angles defined by the light-receiving/trapping surfaces of the absorption enhancement structures may also vary widely from about −5 to +5 degrees with angles in the −45 to 45 degree range being desirable in some cases. Also, the size of the absorption enhancement structures may be varied to practice the invention with some embodiments utilizing absorption enhancement elements as small as about 0.25 mils (5 microns) in width while others use absorption enhancement elements up to 1 inch or more in width. The height (or thickness) may also be varied, with some embodiments being very thin (e.g., about 0.25 mils or 5 microns in height) while others are relatively thick (e.g., up to about 1 inch or more in height). In one exemplary embodiment, a two or three-faceted absorption enhancement structure is utilized that is about 2 mils high and about 1 mil wide at the top planar facet or side of the structure (with the base width or pitch varying with the inward angle of the side(s) of the structure).

The following description begins with a description of use of structures/elements of PV enhancement films for providing increased TIR (e.g., with reference toFIGS. 2-24withFIG. 1showing a solar energy conversion system that may use any of the PV enhancement films described herein in solar array or panel112as film114). However, with this description fully understood, it will be clear to one skilled in the art that absorption enhancement structures/elements optimized for TIR also provide increases in path length in the PV material (just as absorption enhancement structures optimized for optical path length also provide a substantial amount of light capturing functionality or TIR) such that the TIR structures of the figures are absorption enhancement structures useful for improving path lengths (and vice versa). The description then continues with a more detailed look at optimizing the PV enhancement films for optimizing ray path length into the PV materials, e.g., beginning after the discussion ofFIG. 24and with reference toFIG. 25and on. Prior to turning to this more detailed discussion, it may be useful to more generally describe aspects of one or more embodiments of the present invention.

Through efforts to improve PV device efficiency, the inventors have designed and fabricated PV enhancement films with absorption enhancement structures (with a variety of forms and sizes). The PV enhancement films improve the efficiency in at least two ways: (1) by recycling reflected rays through TIR such as with absorption enhancement structures optimized to create TIR and (2) by optimizing or at least improving the desired path length into the PV materials such as with absorption enhancement structures configured to alter the path of the incident light so as to obtain a desired angle of incidence of the rays upon the PV material light receiving surface to increase (or even substantially maximize) the length of the path the light takes as it passes through the PV material for a range of angles of incidence (e.g., for the Sun directly above a panel to plus or minus some amount such as plus or minus 20 to 40 degrees or the like to better collect the Sun's energy at its highest intensities). Typically, the “optimized” path length for a ray of light is the optical path length through the PV material (such as through a thin film silicon-based PV cell or the like) that is the longest distance through the PV material. In contrast (or without use of the absorption enhancement structures), the path length may be near to the shortest path such as at noon or when the Sun is directly above a solar panel or array (and at its highest intensity) and incident light may pass through the material on an orthogonal path (e.g., the path length only being equal to the thickness of the PV material).

Structures or elements on the PV enhancement films may be optimized both for TIR and for increased path length through the PV materials for various incoming ray angles (azimuth) and/or by time of day (e.g., may be more useful to increase path length during prime energy collection periods such as 10 AM to 2 PM, 9 AM to 3 PM, or some other time period of expected higher Sun energy intensities and to enhance TIR at other times). In addition, the rays may have their paths modified or be redirected by the absorption enhancement structures/elements to improve performance of the PV materials or of the PV device at specific band gaps that are customized for the particular PV materials (e.g., shaping/sizing of the absorption enhancement structures may be selected to suit the PV materials, which may involve not simply maximizing the length of the optical path in some cases).

To assist in selecting a configuration for the absorption enhancement structures for a PV enhancement film, a structure optimization module, which is typically implemented as a computer program or software run by one or more processors on a computer or computing device to transform a set of input variables to determine, store in memory, and/or display an output (e.g., a structure design including shape and size), has been created and used by the inventors. Specifically, various data including refractive indexes and thicknesses of the various materials are chosen and provided to the running structure optimization module (e.g., a user interface such as a GUI, a command line interface, or the like is displayed to a user on a computer monitor screen and the user enters refractive indexes and thicknesses of PV enhancement film, a protective glass, one or more layers of adhesive, and PV material(s)). Another input provided to the structure optimization module or tool is a range of incidence angles or incoming ray or sun angles for use in optimization (e.g., plus or minus 40 degrees or the like with 0 degrees being perpendicular to the PV material's light receiving surface).

In other words, the absorption enhancement structures are optimized or selected by the structure optimization module specifically for a range of incoming ray angles. The processor(s) or computer makes calculations for or grinds through all of the angles (e.g., at each angle by whole degree/radian, fraction of a degree/radian, some preset degree offset (such as for each 2, 3, 4 degrees and so on, or the like) for the user-defined PV devices or PV assembly with and without the use or application of the PV enhancement film) to determine an absorption enhancement structure (or combination of such structures when using more than one in a single PV enhancement film) that provides an improved optical path length (e.g., a longest path length, a correct path length for a particular range of band gaps, and so on) for the PV material. In some cases, the structure optimization module or tool acts to process numerous (e.g., millions to billions) combinations over several hours of processing time to determine a result such as an absorption enhancement structure or combination of such structures with side angles (shape, size, and so on in some cases) that optimizes path length.

In some embodiments, a PV enhancement film may be provided with a single absorption enhancement structure design such as elongated structures with a triangular cross section as shown inFIGS. 4 and 5, for example. However, use of the structure optimization module or tool of one or more embodiments of the present invention has shown that it may be usefull to combine two or more absorption enhancement structures that are each designed to provide optimization for differing ranges of angles of incoming/received sunlight and/or to provide differing functionality (e.g., one set of absorption enhancement structures may be designed for optimizing optical path length over a particular range of angles of incidence while another set of absorption enhancement structures may be designed for providing improved TIR, which may be more important at incidence angles outside the range of angles used in designing the first set of structures or may overlap this range by providing TIR enhancements in this range of angles, too).

For example, optimization of an absorption enhancement structure for use with a PV enhancement film for a first range of angles may provide an overall improvement of path lengths relative to the PV device without such as film (sometimes with huge improvements achieved in particular narrow ranges). However, the absorption enhancement structure may have a range of incidence angles where no or little improvement is achieved (e.g., a range of weakness). The inventors found such a situation in a PV enhancement film with absorption enhancement structures optimized/configured for optimizing path length over a range of −40 degrees to +40 degrees. The PV enhancement film was fabricated of a plastic with an index of refraction of 1.49 and each absorption enhancement structure was elongated (such as shown inFIGS. 4 and 5) with a pitch of 13.333 mils and a thickness of 7 mils.FIG. 25shows a graph2500showing path length ratio in PV material compared with angle of incidence on the PV device, with the path length ratio determined at a particular angle of incidence by dividing path length with use of the PV enhancement film by path length without use of such a film and its structures (e.g., with a ratio of 1 showing that the path length had not changed with the addition of the PV enhancement film). As shown with line2510, significant improvements in optical path are achieved for angles of incidence with absolute values over about 10 degrees while an area of no change or “weakness” is found in the range of angles of about −10 to about +10 degrees as shown at2520. The average length ratio was found to be 1.231, which indicates that inclusion of the PV enhancement film with absorption enhancement structures designed as shown inFIGS. 4 and 5with the above defined triangular shape is desirable for providing enhanced path lengths (an average length ratio of 1.231 was achieved) and increasing the efficiency of a PV device.

However, the inventors further understood that such a pattern as shown by line2510with a weak or low improvement zone2520may be less than optimal for a PV enhancement film design. This may be improved upon by providing two or more configurations or designs for the absorption enhancement structures provided upon the PV enhancement film. For example,FIG. 23shows the use of a sawtooth pattern of elongated, triangular-cross section structures with alternating configurations that may be used to address the weak spot2520shown inFIG. 25. One set of the structures may be chosen to provide the ratios as shown inFIG. 25or optimizing path length over plus or minus forty degrees while the second set of structures may be chosen to increase the ratios within the weak spot or the second angle of incidence range of plus or minus 10 degrees. This is significant because it may be desirable to optimize path length of light through the PV materials during the “prime real estate” in solar energy collection, which typically equates to the time from about 10 AM to 2 PM during each day and/or about plus or minus forty degrees. Increasing performance during this prime time of energy collection by even a few percentage points may result in much larger overall increases in the effectiveness and/or efficiency of a PV device.

With these goals in mind,FIG. 26shows a graph of ray path length ratios versus angle of incidence for a solar cell assembly or PV device of an embodiment in accordance with the invention (e.g., as may be provided by the sawtooth arrangement of absorption enhancement structures on a PV enhancement film as shown inFIG. 23or the like). The PV device in this case was modeled as including a PV material (e.g., amorphous silicon or the like with a refractive index of 3.44) with a thickness of 11 mils. A protective cover glass with a thickness of 125 mils and a refractive index of 1.5 was applied to the light-receiving surface of the PV material with an adhesive, which had a thickness of 2 mils and a refractive index of 1.51. The alternating absorption enhancement structures were assumed to have a pitch of 13.333 mils and heights or thicknesses of 7 and 10 mils (arranged in an alternating pattern in this example but other cases may alternate sets of such structures such as 2 to 5 or more of one design and then 2 to 5 or more of the second design).

As shown with line2610, use of the PV enhancement film with this sawtooth pattern of absorption enhancement structures achieves an increase of the path length over the entire range of incidence angles with the average ratio being 1.527. Significantly, the structures chosen to have a pitch of 13.333 mils and a height or thickness of 10 mils (rather than 7 mils) are more optimized for providing an improved path length in the range of incidence angles of plus to minus 10 degrees as shown by the peaks/increases in the path length ration in the region2620in graph2600. Hence, a PV enhancement film with a sawtooth pattern of differing, alternating absorption enhancement structures configured for optimization path lengths over two differing (but sometimes overlapping) ranges of incidence angles may be desirable in some applications to better capture solar energy available during peak or prime energy collection periods as well as throughout the rest of the day. Further, as is discussed in detail below, the PV enhancement film may readily be used to improve the efficiency of an existing PV device (such as a previously manufactured and even installed solar panel or array) that may include a protective layer of glass or the like. In such cases, the optimization and selection of the one or more structures is performed by including the glass and adhesive as well as the PV film and PV material in the optimization process (e.g., as input parameters to the structure optimization module) to choose a more desirable absorption enhancement structure(s).

In general, a premise behind increasing path length is that many PV absorbers (or PV devices/material layers) are not completely ideal in the sense that not all of the photons or available energy is absorbed. Hence, the inventors recognized that increasing path lengths often results in substantially greater absorption of the received sunlight. In fact, use of the PV enhancement film described above with reference toFIG. 26(with a first set (such as about 50 percent) of the absorption enhancement structures optimized for plus/minus 40 degrees and with a second set (such as about 50 percent) of the absorption enhancement structures optimized for plus/minus 10 degrees using a triangular cross section) shows an increase in path length on average of about 53 percent. More importantly, though, such a PV enhancement film with the combined sawtooth structures provided path length increases of about 35 percent in the prime energy collection zone shown at2620of about 35 percent (such as in the range of incidence angles for sunlight of about plus/minus 20 degrees). The significance of this achievement is that depending upon the absorber or PV device/material arrangement, the additional path length can provide substantially more absorption by or into the PV materials and, hence, provide large improvements in efficiencies. Another component providing the improved efficiency and/or energy conversion capacity for a particular PV device is the increase or modification of path length by the absorption enhancement structures of the PV enhancement film, which may increase performance by allowing absorption into a “best” or more efficient band gap for the particular PV material.

Increasing path length with PV enhancement films including optimized absorption enhancement structures may increase absorption in nearly any PV material and/or any PV device such as those with polysilicon and multi-layered silicon, CIGS, amorphous silicon Cad-Tel films, and the like. However, in theory, use of the described PV enhancement films may have the greatest increase or benefit in thinner PV materials such as amorphous silicon thin films. While most traditional PV silicon materials range between about 200 and about 300 microns, amorphous silicon, Cad-Tel, and CIGS PV devices may have thicknesses of less than about 25 microns, which presents a much shorter optical path length through PV devices fabricated with this thin film PV material and, in some cases, allows less possible absorption of photons/energy. Hence, increasing the path length of the received/incident rays or sunlight is likely to be more important for these thinner films and often will result in higher or more substantial increases in overall efficiencies.

One of the most practical aftermarket products using the PV enhancement films described herein may be retrofitting or modifying PV materials and PV devices (such as solar cells/arrays). In such cases, the PV enhancement films can by applied such as with a thin film/layer of adhesive (or about the edges) over the PV device. Many existing/installed panels, arrays, and cells include glass tops or glass protective covers over the PV materials, with the layer of glass glued with adhesive to the PV material (with or without a layer(s) of AR material or coating). With this in mind, the structure optimization process (or use of the structure optimization module) may anticipate the end use of the PV enhancement film with the input variables and/or optimization information including information about the glass cover and adhesive. In this way, the PV enhancement film and its structures may be optimized for use with a particular glass cover (e.g., a particular PV device design) with absorption enhancement structures selected to suit the cover and a particular adhesive (or range of anticipated protective covers and/or adhesives). In other embodiments, though, the PV enhancement film may be attached directly to the PV material (e.g., take the place of the protective glass cover/top), and in such cases, the film may be formed of plastic or glass and be adapted to provide the desired amount of path length modification and/or TIR without concern for an intervening glass cover.

FIG. 1is a functional block or schematic view of a solar energy conversion system100in accordance with an embodiment of the invention. As shown, a light or energy source102, such as the Sun, transmits energy, rays, or sunlight104(often termed “solar energy” or “solar power” made up of nearly parallel light rays due to the distance between the Sun102and the array112) onto a solar energy collection assembly110. The assembly110includes a solar array or panel112that generally would include numerous solar cells (not shown inFIG. 1) that each are formed of PV structures designed to convert solar energy104into electricity120. The assembly110may be rigidly mounted to generally face the Sun102such as on, in the northern hemisphere, a southern exposure portion of a building roof or in solar farm, or the assembly110may include tracking components118that move and position the solar array/panel112to follow the Sun102such that the sunlight104is always or more often orthogonal to the receiving surface of the array112(and included solar cells).

Electricity120generated by the solar cells or PV structures of the solar array112may be provided to a variety of end use devices such as charging electronics130for storage in a battery or batteries132, a power grid140(e.g., for use by a utility to meet residential and commercial power demands), and/or other electrical loads150. One of the largest problems with the use of PV arrays112is efficiency in converting the solar energy104into electricity that can be used by the end users (battery132, power grid140, and/or electrical load150). Some estimate that existing solar arrays may only be 10 percent efficient in generating the electricity120, e.g., generate 100 W/m2from the received solar energy104of 1 kW/m2. There are also inefficiencies and line losses in the transmittance and storage of the electricity120that may result in an end-to-end efficiency of even less than 10 percent (e.g., 7 to 8 percent by some industry estimates).

The present invention is directed toward increasing the efficiency of PV devices such as the solar array112, and the inventors recognize that a significant portion of the solar energy104incident upon a typical solar array112may be lost as shown at106due to reflection or bounce back. For example, losses in absorption of PV materials in the solar array112may be caused by normal cosine fall off or the lack of absorption due to the incoming angle of the sunlight104with relation to the structures in the PV materials. Even when tracking118is utilized, a portion106of the sunlight104is lost due to reflection (such as off of a protective glass surface, due to surface irregularities, and so on).

For example,FIG. 2illustrates a solar cell210that may be included within the array112, and, due to manufacturing techniques (or even by intentional design) the light-receiving surface or front side212of the cell210may be irregular or be textured (e.g., not planar). As a result, sunlight220that strikes the cell surface212even at a zero degree angle of incidence may be deflected as shown at224,225,226,227while other rays or photons222are absorbed by the PV materials or structures of the cell210and converted into electricity. The problem with deflection of rays224,225,226,227(or rays106inFIG. 1) is worsened when no tracking is provided such that the rays104,220strike the surface212(or solar array112) at oblique angles (e.g., angles less than or greater than normal or zero degrees as measured from normal to the surface212or light-receiving surface(s) of array112or its solar cells).

With reference again toFIG. 1, one solution to improve the efficiency of the collection assembly110(or of array112) is to bounce at least a portion or fraction of the unabsorbed rays104back into/onto the PV materials (or solar cells) of the solar array112, which reduces the amount of solar energy106that is lost from the system100. To this end, a PV enhancement film114is positioned over all or a subset of the solar cells or PV material of the array112to trap at least a fraction or portion of light reflected or deflected off of the surfaces of the array112without being absorbed and redirect it back at least once onto the array112to increase chances of absorption and generation of electricity120. The film114includes a plurality of TIR structures or elements on the surface receiving the sunlight104, and each of these structures or elements are adapted to make use of TIR techniques to allow incoming rays104to enter and strike the solar cells/PV materials of array112while also promoting or enhancing the possibility of rays bouncing back onto the solar cells/PV materials if not absorbed (e.g., if reflected/deflected off light-receiving surfaces/structures in array112). As will be explained more below, each TIR structure on film114is a shape formed on the light-receiving surface of the film114in order to provide TIR of reflected or deflected rays. In essence, the TIR structures are “reverse funnels” that allow rays to enter but act to deflect rays back to the PV materials of the array112by design as those reflected/deflected rays try to exit, as lost rays106, away from the PV material at certain angles. The TIR structures of film114continue to deflect a portion or fraction of the unabsorbed rays or sunlight such that the trapped and/or deflected rays within the film114are directed back to the PV materials, thereby increasing efficiencies of the materials and array112from about 5 to 20 percent up to 10 to 25 percent or more in some cases.

The film114may be retrofitted onto an existing solar array112or combined with new PV materials or solar cells during initial fabrication of the array112, with either fabrication method of the array being performed relatively inexpensively (e.g., a plastic film114with numerous TIR structures may be attached with adhesives or other methods in a few minutes even after the array112is in position in a solar farm/plantation or a rooftop setting or may be laminated or otherwise applied over the solar cells of an array or over each solar cell as it is formed (e.g., the film114may include a plurality of segments or individual films each applied to a solar cell to form a solar cell assembly that may then be included within the array112)). The film114(or films as may useful to provide desired coverage of a larger array112) may be made of a wide variety of materials such as readily available plastics that are transmissive to sunlight104such as a polymeric sheet or the like or made of glass or certain ceramics that are transparent or at least highly transmissive. In some embodiments, the materials used for forming the film114and its TIR structures/elements are chosen from glass, nearly any type of clear (i.e., transparent to translucent/less transmissive) plastic including but not limited to PET, propylene, OPP, PVC, APET, acrylic, or any clear plastic, and/or a ceramic. In many embodiments, the preferred base material is a plastic due to its durability, low material and manufacturing costs, and light weight, and the plastic of the film114may be extruded, calendared, cast, or molded to provide the functional TIR structures described herein.

The TIR structures included on the PV enhancement films of embodiments of the invention function to create TIR on the light-receiving surfaces of solar cells/PV materials, and the TIR structures may be described as “reverse funnels” for directing lightFIGS. 3A-3Cillustrate a conventional funnel or cone structure300, an inverted funnel or cone structure320(e.g., with its larger portion used as its lower or base portion), and a funnel or cone structure350with mirrored walls. In describing attempts to direct or herd light rays, the rays of light do not react or behave as initial logic may suggest such as if one attempted to treat light as a fluid and apply fluid dynamics principles. In fact, light may be thought of as acting in an opposite fashion as a liquid in a funnel. In other words, when creating a funnel for fluids, the fluid will behave under the force of gravity in a predictable manner with gravity pulling the fluid from a larger end of the funnel to the smaller portion and the exit (e.g., funneling oil into a vehicle or the like with the exit having a smaller diameter). In contrast, when structures are created with mirrors, glass, or other reflective materials with narrowing pathways, the opposite effect happens when light is directed into the light “funnel.”

FIG. 3Ashows a funnel structure300in a material with an index of refraction of 1.49 and non-reflective walls. The incoming rays312are reflected as rays314that undergo smaller angles of reflection until the rays316finally escape from the surface or sidewall310of the cone/funnel structure300. In contrast, as shown inFIG. 3B, an inverted funnel structure320allows received or incident light332to enter and continue on or be focused as shown at334and336through the larger opening of structure320(e.g., a ray entering a cone of a material with an index of refraction of 1.49 undergoing TIR).FIG. 3Cillustrates for example of a cone structure350with reflective or mirrored sidewalls352and an index of refraction of 1.49 arranged with a narrowing diameter (e.g., a truncated or frustoconical shaped structure300). An attempt to funnel incoming or received light rays354results in the light actually backing out as shown at354of the funnel structure356by being deflected/reflected off the narrowing walls352(e.g., the rays are reflected off the walls352at angles that sequentially differ such that they get reflected back out of the cone350such that rays that would normally escape from the funnel tip are reflected back up the funnel). The inventors recognized that the structure (or other “funnel” structures)350could be utilized to trap unabsorbed sunlight within a solar array or solar cell when the ray354is considered a photon or ray of sunlight that is being deflected or reflected from the cell or PV materials. In other words, the TIR elements/structures are arranged as inverted funnels as shown inFIG. 3B(or inverted versions of those shown inFIGS. 3A and 3C) upon the solar cells (or arrays) such that incident light is allowed to enter and be focused upon a solar cell/PV material while unabsorbed light is deflected back for a second (or third or more) chance for absorption.

The concept of using TIR in thin films (e.g., plastic films with a substrate with TIR structures on one side that are applied over solar cells) is believed to be a new concept. In order to use TIR as a method of turning rays or limiting loss of sunlight from a solar cell/PV material, it may be useful to describe basic physics or geometry of the angles and the resulting behavior of the rays. Sunlight or rays may enter into a transmissive TIR structure or element with refractive indexes of between 1.1 and about 2.0, with normal ideals between 1.4 and 1.65. Once rays enter the TIR structures, the rays will not exit the TIR structure if they remain within 42 degrees of parallel to the wall of the structure when striking the wall of the structure. Rays within this TIR physics law will deflect inside the TIR structure until they find an escape or are absorbed by the PV materials/solar cell and are converted into electricity. The “escape” out of the TIR structure would typically be the result of a deflection of past 42 degrees as measured from wall of the TIR structure (e.g., an internal “surface” of a wall or facet of a TIR structure that comprises a solid body of plastic, glass, ceramic, or other highly transmissive material), creating a more direct “strike” of the surface allowing the rays to exit.

One idea supporting the invention is that many losses and decreases in efficiency in various PV films are the result of rays not being absorbed into the PV material, e.g., absorption of photons to start the photovoltaic effect (i.e., process of the electron moving down (creating a hole) to be replaced by an electron of the opposite polarity and therefore creating a flow of electrons to establish a current). Instead, the rays bounce off the three-dimensional (3D) surface or non-planar/textured surface of the PV materials or solar cell, whether the film is using silicate, cadmium telluride or other technology or materials. Since the goal of a solar cell design is for the rays to enter the PV film, and, therefore, the structures, PV films can be made of many layers, targeting the various wavelengths of the incident sunlight. Since a large portion of the solar energy lies in the shorter wavelengths for the PV process, these wavelengths are specifically targeted either on one or more layers for absorption. PV materials are often made of a pure material such as silicon mixed with tiny amounts of controlled impurities to produce controlled energy levels or bands in the material. Depending on the materials and amounts used there are valence bands and conduction bands. The photons coming from a source of light will cause electrons to occupy conduction bands that can conduct electrons to an electrode. On the other side of the material, there are holes that are effectively positive charges that were produced by the photons that traveled to the electrode on the other side of the PV material to complete the electric circuit. It is not the purpose here to dwell on these processes that are covered in solid state physics textbooks and available reference materials but to generally say that when photons are absorbed under the right conditions an electrical output will be generated.

One of the main problems with the ray absorption into PV materials is that incoming rays tend to bounce off the surface of the PV materials at extreme angles, significantly decreasing the ray's chance of absorption. This is attributed generally to a phenomenon known as cosine fall off. In this case, the incoming rays are coming in from difficult angles in the mornings, evenings, and/or differing seasons (or a combination thereof) that allow an undesirably small fraction or portion of the rays to be absorbed by the solar cell or array containing numerous solar cells. In addition, improper orientation of panels/panels with regard to the azimuth of the Sun may also contribute to or lead to loss of available solar energy.

It is important to note, however, that even with perfect tracking of the sun with PV materials, the angles of the structures themselves create a random-like mathematical percentage of rays bouncing off structures within the PV film and not being absorbed. Even short wave length rays coming in directly may hit structures or textured surfaces of a solar cell at angles that do not allow absorption (as shown inFIG. 2). While certain types of coatings (e.g., AR coatings) can help improve efficiencies by reducing reflection in some cases, the nature of the present invention differs as it provides a method that makes use of TIR to improve solar energy conversion efficiencies of solar cells and other PV devices (and of solar panels/arrays incorporating such solar cells and PV enhancement films). The PV enhancement films include TIR structures/elements that allow the incoming or incident rays to enter unencumbered through the micro-structured film (e.g., a sheet of plastic, glass, or ceramic with TIR elements on one side without shading (such as is the case with the micro-mirror systems)). Then, if a ray is reflected from the surface of the PV structures, each TIR structure is designed with an ability to create TIR, e.g., based on the angle of deflection parallel to the pathway of exit of that ray (which must be less than 42 degrees as measured from the wall of the TIR structure upon which the ray strikes). The trapped or deflected ray continues to “bounce” off of the internal structure of the TIR element at least once, possibly two, three, or more times based upon the shape of the structure and to “strike” the PV surface again (at least a second time) for possible absorption.

In fact, this TIR effect may happen a few times up to dozens of times until the ray is absorbed into the PV material generating energy or exits the structure because of a deflection creating an angle that exceeds 42 degrees (a more direct “hit”) to the wall of the structure. Therefore, use of a PV enhancement film with TIR elements/structures with a solar cell/PV device in accordance of invention does not insure the absorption of each ray, but it does increase the odds of absorption by giving a portion or fraction of the unabsorbed rays another chance or opportunity at absorption by bouncing the ray back to the PV material at a different angle (at least the probability is that the ray will be incident upon the solar cell at a different angle than when first received). In many cases, a ray, if rejected again by the PV material with a deflection, will in theory have dozens more chances of absorption. Ultimately, the ray will either be absorbed or will find an exit angle from the structure that exceeds 42 degrees from parallel of the surface of the wall of exit. In ray tracing programs run by the inventors to test use of TIR structures/elements of the invention, using a 95% reflective mirrored surface in place of a light-receiving surface of a solar cell shows that rays may bounce dozens of times within the structures before exiting the structure. In other words, the TIR elements or microstructures can increase a deflected ray's odds of being absorbed by a significant amount or by many times in this TIR light-trapping process.

FIG. 4illustrates a solar cell (or PV device) assembly400in accordance with one embodiment of the invention. As shown, the assembly400includes a solar cell or PV device410(such as a silicon-based solar cell, a thin-film device, a GaAs/Ge solar cell, and nearly any other PV design) with a rear or back surface (e.g., a back contact)412and a front or light-receiving surface414(e.g., a front contact covering PV materials such as p-semiconductor layer as may be found in a silicon solar cell/wafer design, an AR coating, a glass or other protective layer, or other surface directed toward the Sun in a solar cell design). Since a significant portion of incident light upon the light-receiving surface414of the solar cell may be reflected, deflected, or otherwise unabsorbed, the assembly400also includes a PV enhancement film420. The film, sheet, or layer420is positioned to cover all or a portion of the light-receiving surface414and may be applied or attached via an adhesive layer418(e.g., a substantially transparent or at least translucent adhesive) such that the film420abuts or is positioned proximate to the surface414of cell410. In other embodiments, other mounting methods such as mechanical methods or direct lamination onto the surface414may be used to provide the film420on the cell410(and, in other cases, the film420may be provided as an integral layer or portion of the cell410such as part of formation of a protective glass, plastic, or ceramic coating on the cell410). In some cases, the PV enhancement film420will be manufactured separately from the cell410and applied later as a modification or retrofit (e.g., to a cell410already in use in a solar array or module in a solar farm or on a roof mounting) while in some cases the PV enhancement film420is provided on the cell410as part of the original fabrication of the cell410and assembly400.

As shown, the PV enhancement film420includes a substrate426with a first side/surface422that is positioned proximate to the front or light-receiving surface414of the solar cell410(and may be considered a solar cell-facing or mating surface). The substrate426is generally a relatively thin layer formed of substantially transparent material (e.g., the same material as used for the TIR structures428) and the cell-mating surface422often is generally planar to provide minimal interference with light passing from the PV enhancement film420to the cell410. On a second side/surface424of the substrate426, the PV enhancement film420includes a plurality of TIR structures or elements428. The side/surface424may be thought of as the light-receiving surface/side of the film420and is spaced apart from the cell surface414by the thickness of the substrate426. In this embodiment, the TIR elements428are two-sided or two-faceted structures with elongated bodies extending over the length (or width) of the solar cell410surface414as is shown with the length of the film, LPV film. The TIR elements428are linear elements with a triangular cross section in this embodiment with the two facets or sides of the structure428forming the sides of the triangle and the base mating with or being an integral connection with the substrate426. The size and shape of the triangular cross section of each TIR element428may be varied to practice the invention, and it may be varied depending on the intended use of the cell assembly400(e.g., 45 degree facets may be used for a cell assembly400used in a solar array (seeFIG. 1) that is used with tracking such that sunlight is typically receiving with an orthogonal orientation while smaller (or larger) facet or side angles may be useful when no tracking is provided and a large portion of the sunlight strikes the cell assembly at oblique angles). The PV enhancement film420may be considered a “sawtooth” design with the TIR elements428being the teeth of a saw blade.

FIG. 5illustrates an enlarged end view of the solar cell assembly400during use to trap sunlight showing details for a single TIR element428of the PV enhancement film420. As shown, the PV enhancement film420has a thickness, tPV film, made up of the thickness of the substrate426and the thickness or height, HTIR element, of each TIR element428. The thickness of the film, tPV film, typically will range from up to about 1 micron to about 0.25 inches, with the substrate426having a thickness to facilitate structural integrity of the PV enhancement film420and facilitate manufacturing. Each TIR element428has a width, WTIR element, that will also vary to practice the invention and will depend upon the facet or side angles, θ1and θ2, will typically be up to 1 micron to 1 inch or more. The facet-defining angles, θ1and θ2, are typically equal such that the triangular cross section of the TIR element428is an isosceles triangle, but this is not required to practice the invention. In one embodiment, the facet-defining angles, θ1and θ2, are chosen to be less than about 45 degrees (as measured from a plane parallel to the surface422of substrate426or from a second side of substrate422from which the TIR elements428protrude, which is also parallel to the surface422), with 45 degrees being useful when received solar energy is generally orthogonal to the light-receiving surface414of the solar cell410and smaller angles being useful when rays are received at more oblique angles.

As shown in use, a first ray521of sunlight is received or is incident upon a side or facet510of the TIR element428at an angle that is near normal or orthogonal (as measured from a plane orthogonal or normal to the light receiving surface414of the solar cell410with the ray521being shown at about −10 degrees). The received sunlight521is allowed to enter or pass through the TIR element428with some diffraction as shown with ray522, and the ray522passes through the PV enhancement film420including the substrate426where it strikes the light receiving surface414(and/or PV structures) of cell410. In this example, the ray522is not absorbed to make electricity but is instead reflected or bounced off at a different angle as shown with ray524. The ray524strikes the side or facet520of the TIR element428at an angle, α, and when this angle is less than about 42 degrees (as shown), the ray is trapped by facet520and reflected as shown with ray526back toward the light receiving surface414of cell410(e.g., a TIR effect is achieved with TIR element428). Again, the ray526may not be absorbed by the solar cell410and instead reflected/bounced back as shown at528where it strikes the facet520to again be trapped/reflected at a differing angle as ray530. Ray530strikes the light receiving surface414of the cell410, where it is absorbed into the cell410as shown with absorbed energy/ray532.

In this example, the TIR element428trapped the non-absorbed rays524,528using TIR and provided the solar cell410with two additional chances to absorb the solar energy, which otherwise would have been lost (e.g., if conventional AR coating had been used the ray524would likely have been lost from the assembly400). In practice, the number of additional chances will vary widely and will likely range from 0 to 12 or more (with 0 occurring when the first reflected ray524strikes the facet520at an angle, α, greater than 42 degrees), with a general description being that the TIR element428acting to trap at least a fraction of the reflected light and direct it back onto the light-receiving surface414for one or more chances at absorption. For example, a cell410may experience up to 70 percent loss of sunlight due to reflection and/or bounce off of received rays from the light-receiving surface414, and the PV enhancement film420with use of the TIR elements428(linear bodies with two-sided cross sectional shapes) may be able to force 35 percent or more of the lost sunlight to strike the light receiving surface414at least a second time (with some rays being trapped and forced to strike the surface414multiple times by the TIR element428).

Similarly, other rays540may strike the TIR element428at differing angles (such as at more than 20 degrees as shown) and be allowed to enter the TIR element428as shown with ray542. The ray542passes through the TIR element428and strikes the light-receiving surface414of the cell410where it is reflected or bounced off as ray544. The ray544strikes the facet/side520at an angle, β, less than about 42 degrees (in this case), and is deflected as ray546, which strikes surface414of cell410and is again reflected as ray548. The unabsorbed ray548strikes facet510is again trapped by TIR and reflected as ray550toward the light-receiving surface414, but this additional chance provided by the TIR element428results in the ray550being absorbed as shown at554. It will be understood thatFIG. 5represents a greatly simplified description of the use of a PV enhancement film420with TIR elements428as numerous rays would be striking the TIR elements428along their lengths and across both facets510,520, and a large portion or fraction is absorbed by the solar cell410upon initial contact. But,FIG. 5is useful for understanding how the PV enhancement film420may be used to provide TIR structures or elements428over the light-receiving surface414of a solar cell410to capture at least a fraction of the rays that are not absorbed by the cell410so as to increase the efficiency of the solar cell410by providing the PV structures/components of the cell410additional chances to absorb the rays. The “second chance” rays or trapped rays will typically strike the surface414at a different location than the initial receipt location and at a different angle, which may also increase the odds that the rays will be absorbed by the cell410.

The shape of and/or wall angles the TIR element may be altered in accordance with the invention to provide better or differing TIR effects (or differing abilities to trap light on the solar cell/PV device front or light-receiving surface). For example, the inventors believe it may be beneficial to utilize TIR structures with 3 or more facets/sides to trap sunlight received over a range of angles (e.g., when tracking is not provided for a solar array or the like).FIG. 6illustrates an end view similar to that ofFIG. 5of a solar cell assembly600with a PV enhancement film610applied to (or positioned over/adjacent) a solar cell. In this case, the PV enhancement film610is formed with a substrate612abutting the solar cell and supporting on an opposite side a plurality of linear (or elongated) TIR elements614. Each TIR element614has a three-sided cross section, with first and second sides616and620that may be angled inward to meet a top side/surface618. The top surface/side618may be planar and parallel to substrate612(or its side that abuts the solar cell) and the angled sides616,620may be angle inward at a range of angles such as up to about 15 degrees to about 45 degrees or more. Light incident upon the assembly600is shown at602as may be the case at noon or when tracking is used, and such orthogonal rays602may generally pass through the film610for substantial absorption by the cell components. In contrast, rays603that are more oblique to the cell and substrate612may strike one of the facets616,618,620and pass through the substrate612and one or more layers/components of the solar cell, with received ray604shown passing through an AR coating634, a protective glass layer632and an upper contact630. At this point (or earlier), the ray605is reflected or bounced back toward the PV enhancement film610where it strikes the same or another facet616,618,620and is deflected as ray606. It may be directed toward the solar cell or to strike yet another facet616,618,620as trapped/TIR-captured ray607for absorption upon this second (third, fourth, or later) opportunity provided by the PV enhancement film610. As with other films, the substrate612and the TIR elements614typically are formed of the same materials such as a plastic, a glass, and/or a ceramic that is substantially transparent (i.e., relatively highly transmissive) to light602such as by extrusion or other pattern forming on a sheet or film of plastic or the like.

As will be understood, the PV enhancement films such as film610may be used with nearly any solar cell design and/or PV component where reflection or loss of incident light is a concern.FIG. 6illustrates a relatively common solar cell arrangement that may be used in a solar cell assembly600for exemplary purposes. The solar cell includes a back metallic contact670and a front contact (e.g., a transparent conductive oxide (TCO) electrode such as tin oxide, zinc oxide, aluminum-doped zinc oxide, indium tin oxide, and the like)630. Sandwiched between these cell components is a thin-film solar cell layer640(such as a semiconductor film including one or more semiconductor layers such as amorphous silicon with n-type and p-type conductivity regions, CdS/CdTe-based solar cells, crystalline solar cells, and the like with the particular type of solar cell layer used not being limiting to the invention and use of a PV enhancement film), and, in this case, an optional reflection component660is provided, e.g., a reflection enhancement oxide or ethyl vinyl acetate (EVA) layer, a reflection grating etched on the backside of the substrate and a textured photonic crystal as a backside reflector, or the like. Additionally, a protective glass632may be provided to protect the solar cell layer640and front electrode630, and this is often the case in assemblies600in which the PV enhancement film610is retrofitted onto a previously built and/or installed solar cell (or solar array with a plurality of solar cells). An AR coating634(e.g., a metal fluoride and silica composite or the like) may be included in such cases to control reflection from the glass632(e.g., the AR coating634may be found in many existing solar cells that include a glass coating632).

FIG. 7illustrates another embodiment of a solar cell assembly710that includes a solar cell720and a PV enhancement film730. In this embodiment, the solar cell720may include a substrate721that may serve as one of the cell's electrodes, with a layer722deposited thereon. The layer722may be a silicon layer or other layer useful for absorbing solar energy. For example, the layer722may be formed as a Si-layer doped and otherwise formed to provide a n-type semiconductor. A p-type semiconductor724may then be formed upon the n-type semiconductor layer722in such a manner that results in a textured or rough surface725(e.g., with a plurality of pyramids or the like). A front or counter electrode726is formed with or over the layer724to form the solar cell720. As may be expected, the roughness or texture of the light-receiving surface725of the solar cell720may result in a portion of incident light being reflected or deflected and not absorbed by the layers722,724to generate electricity.

To enhance the efficiency of the cell720, the solar cell assembly710includes a PV enhancement film730that is positioned over, and may be joined to, the front electrode726so as to substantially or completely cover the light-receiving surface725. The PV enhancement film730is similar to the other films shown thus far in that it includes a substrate732of substantially transparent material upon which a plurality of linear or elongated TIR elements734are formed (or otherwise provided such as by a second depositing step or the like). The film730differs, though, as the TIR structures are formed with an arcuate light receiving/trapping surface such that each TIR structure may be considered to have a semi-circular cross section (e.g., the body of each TIR element734may be thought of as half or less of a cylinder). The TIR elements734are aligned with their elongated bodies side-by-side and with their longitudinal or central axes parallel. Again, the height and width of the TIR elements734may be widely varied to practice the invention and to achieve a desired TIR effect (e.g., better TIR at particular angles of incidence of received sunlight and so on to suit a particular solar cell720). For example, each TIR element may be up to 0.25 inches in height but typically may be relatively thin such as several mils or less in height and may be up to about 1 inch in width but typically10or more TIR elements734are provided per inch or width of the film730.

In some embodiments, PV enhancement films are provided with numerous TIR structures or elements formed upon a surface of a substrate and the TIR structures do not have elongated or linear bodies. For example,FIGS. 8 and 9illustrate another embodiment of a PV enhancement film800that may be used with any of the solar cells shown herein or, more typically, with a solar array of such cells as shown inFIG. 1. The PV enhancement film800includes a substrate810with an upper or light receiving surface812(the opposite surface of the substrate810typically is positioned against or near the light-receiving surface of a solar cell or solar array/module/panel). On the substrate surface812, numerous TIR structures820are formed or provided to trap light using TIR. The TIR structures820may be considered inverse funnels with a frustoconical shape defined by an angled inward sidewall824that extends about the circumference of the structure820and upward to a top or upper surface828. The funnel-shaped TIR structure820has its larger wider “opening” (with a first diameter) or its base against the surface812of the substrate810and angles inward at an angle, γ, such that its smaller “opening” (with a second diameter smaller than the first diameter) at surface828is part of the light receiving surface. In this arrangement, as explained with reference toFIGS. 3A and 3B, incident or received sunlight or rays are allowed to enter the funnel-shaped TIR element820but have more difficulty exiting and are trapped by TIR. The angle, γ, is typically less than about 60 degrees and more typically less than 45 degrees, the height of the structures820is typically relatively small such as less than about 1 inch and more typically, less than 0.25 inches (e.g., 1 to 3 mils or the like), and the diameters of the base and at surface828are typically relatively small such as less than about 1 inch but more typically less than 0.25 inches (e.g., less than about 5 mils or the like). The TIR elements820may be spaced apart on surface812of substrate810but more typically little or no space is provided between adjacent ones and/or rows of the TIR elements820to provide more TIR and trapping of reflected light. The TIR elements820function to provide trapping of reflected light in a manner similar to that shown for the TIR elements ofFIG. 6but in a 3D manner rather than a 2D or linear manner.

FIGS. 10 and 11illustrate yet another PV enhancement film1000in accordance with the present invention that may be used with solar cells such as an additional layer or component of a solar array as shown inFIG. 1. As with the film800, the film1000includes numerous, non-linear TIR elements1020formed upon a surface1012of the film substrate1010. The TIR elements1020in this case are shaped as small domes defined by a light receiving/trapping surface or wall1024that is shaped such that each dome1020has a semi-circular cross section but overall has a hemispherical shaped body defined by a width of a base (or base diameter), WBase, and a dome/body height, HDome(e.g., a base width of less than about 1 inch and more typically quite small such as less than 0.25 inches such as less than several mils and a dome height that is also relatively small such as less than about 1 inch and more typically less than 0.25 inches such as less then several mils). Again, the TIR elements1020may be spaced apart but more typically are tightly spaced upon the surface1012to trap a larger percentage of reflected light. Differing sized and shaped TIR elements may be used in a single film, but to facilitate manufacturing and provide relatively consistent use of a PV device/materials, each of the TIR elements1020is substantially identical in shape and design.

The above description provides a general description of applications for a PV enhancement film with TIR structures or elements to improve the efficiencies of solar cells (or other PV devices) and of solar arrays, modules, and panels that incorporate such solar cells and PV enhancement films. The above description provides description of some PV enhancement films and TIR elements, and it also provides an introduction into how the TIR elements trap light using TIR to direct at least a fraction or portion of reflected (unabsorbed) sunlight back onto the solar cell/PV structures. At this point, it may be useful to provide additional explanation of the operation of TIR elements provided in PV enhancement films, and the following description provides additional embodiments of PV enhancement films along with a more detailed explanation of the optical principles utilized by the invention. Portions of the description include PV enhancement films and TIR elements shown more schematically than in prior descriptions/figures, but it will be understood that such embodiments or models used for computer-simulations and ray tracings may readily be implemented in physical products (e.g., TIR structures or elements provided on a side of a substrate or film of plastic, glass, ceramic, or substantially transparent material) for application over solar cells/solar arrays as discussed above.

This invention generally concerns the use of optical films (e.g., PV enhancement films) that make use of total internal reflection (TIR) and refraction (e.g., TIR structures or elements that provide TIR and also refraction). The TIR elements redirect sunlight reflected off the surface of a photovoltaic (PV) cell back to the cell so that energy that would be normally be lost for electrical power generation is used for (or at least available for) power generation, thus producing more power than if the cell did not have the optical or PV enhancement film as part of its assembly or covering it in a solar array. Embodiments of the invention make use of the properties of light reflection expressed by Fresnel reflection coefficients.

Relevant equations for modeling and/or evaluation of PV enhancement films and solar cells without such films can be written in the following manner: θ1=angle of incidence; θ2=angle of reflection; Rs=power in plane perpendicular to incidence; Rp=power in plane of incidence; Rs=(sin(θ2−θ1)/sin(θ2+θ1))^2; Rp=(tan(θ2−θ1)/tan(θ2+θ1))^2. A plot or graph1200is shown inFIG. 12of the Fresnel reflection as a function of angle for light in a medium of index 1.00 intersecting a medium of index 1.49 with lines1210,1220, and1230representing average reflection, light polarized parallel to plane, and light polarized perpendicular to plane, respectively. The curves of graph1200show that about 4 percent of the light is reflected at normal incidence. As shown, the average amount of light reflected slowly increases to about 70 degrees and then the amount reflected increases rapidly with increasing angle. The curve1210is the total energy reflected. In the case where the light is in a medium of index 1.49 and passes to a medium of index 1.00,FIG. 13illustrates a plot or graph of light reflection1300with lines1310,1320, and1330representing average reflection, light polarized parallel to plane, and light polarized perpendicular to plane, respectively.

In this case,FIG. 13shows with line1310that the average amount of reflected light slowly increases up to about 35 degrees of incidence and then very rapidly increases at about 42 degrees where all of the light is reflected or total internal reflection occurs (TIR). One base idea of the invention is to have an optical material shaped so as to allow the maximum amount of energy (or a significant portion) to reach the PV material of the solar cell/PV device (e.g., provide numerous TIR elements on a PV enhancement film). The reflected portion of light, which would otherwise go to waste, reflects off of the optical material at an angle that gives TIR so that it strikes the PV material at least a second time (and, in some cases, a third, fourth, or “N” times). In another case, refraction is used and will be discussed later (hence, the TIR elements/structures may use TIR, refraction, and/or other optical techniques to trap reflected light and/or direct it back toward the PV materials of a cell and are not limited to “total” internal reflection). The graphs1200and1300ofFIGS. 12 and 13show how this might be done. The amount of light lost to reflection when light enters a higher index of material is not high in the 40 to 50-degree angles of incidence region but when light exits at that angle it is mostly reflected (again, remember the funnel concepts described earlier where light may be received by a TIR element as described here but when reflected from a solar cell's light-receiving surface it may be reflected back to the surface for possible absorption).

For example, the TIR structure1410shown inFIG. 14makes use of TIR to redirect light that has been reflected from the PV surface1411(which inFIG. 14is assumed to be 95 percent reflective or a mirrored surface for showing functionality of the TIR structure1410). As described earlier, the TIR structure1410may be formed of a substrate1412and two or more facets or sides1414,1416(shown at angled offsets from the substrate in the range of 20 to 30 degrees but, of course, many other facet/side angles may be used to define the facets1414,1416and the TIR element1410). The TIR structure1410modeled by this ray tracing had a pitch or base width of 20 mils and a thickness or height of the peak (mating line between the facets1414,1416) of 2.1 mils. The modeled TIR element1410may be a linear or elongated structure withFIG. 14representing an end view or cross section or it may be a standalone or unitary component with a circular cross section along its central axis (passing through the peak between facets1414,1416) and a side sectional view as shown when a plane is passed through central axis and cylindrical body (e.g., seeFIGS. 8-11for illustration of similar unitary or non-linear TIR elements). The TIR element1410was assumed to be formed of a material (such as a plastic) with a refractive index in the range of 1.4 to 1.6 (e.g., about 1.47), and the traced rays1420were assumed to strike the TIR element1410at an angles of incidence of about −30 degrees (as measured from normal or orthogonal to the substrate (and light-receiving surface1411).

FIG. 14shows a ray tracing in which rays have been ray traced through the TIR structure1410(e.g., when combined with other similar structures could provide a saw tooth structure in a PV enhancement film as shown inFIG. 4). The tracing shows rays1420enter the structure with little loss but when exiting after reflecting off a PV surface1411are reflected back to the surface1411for a second (or third or more) chance for absorption. For example, incident ray1421is shown to pass into the TIR structure1420after striking outer surface of facet1414with some refraction as shown with ray1422traveling through TIR element body and substrate1412. The ray1422is not absorbed but is instead reflected as ray1423, which strikes the inner “surface” of the facet1414. Since this angle is less than about 42 degrees, TIR causes it to be reflected/directed as ray1424back to surface1411. Upon this second chance/second striking of surface1411, the PV material may absorb the ray1424or, as shown in this example, the reflection may continue with ray1425striking the inner surface of the second facet1416and being reflected again as ray1426toward surface1411. In this example, the ray1421and its energy was presented to the light-receiving surface not just once as ray1422but also two additional times as rays1424and1426, which also struck at differing angles that may further enhance the odds/chances of successful absorption by an operating solar cell.

Of course, the TIR element1410is not able to trap all rays1420but, instead, only a fraction or portion of the rays1420is redirected toward the surface1411at any particular angle of incidence. For example, ray1430strikes facet1414and is received as ray1431for its first chance at absorption as it strikes light-receiving surface1411. However, if it is not absorbed, the ray1432may be reflected in such a way from surface1411that is strikes facet1416at an angle greater than about 42 degrees. In this case, as shown, the light is lost from the TIR element1410as shown with ray1433. Hence, while the PV enhancement films with TIR structures1410of the invention may enhance efficiency of a solar cell or PV device in receiving available sunlight, the TIR structures1410attempt to enhance efficiencies by increasing light capture and are designed to increase light capture for particular uses and/or solar array or cell designs (e.g., a differing TIR structure may be used for a solar array that tracks the Sun than for a solar array with no tracking).

One method of testing or verifying a design of a PV enhancement film and/or a TIR structure design is to plot ray or light intensity received by or striking a solar cell's light-receiving surface with and without use of the PV enhancement film.FIG. 15illustrates a graph1500of the ray intensity received by a PV or light-receiving surface (such as surface1411ofFIG. 14) as a function of the angle of incidence. In this plot, a TIR element similar to the element1410was modeled, but, in this case, the pitch or base width was about 10 mils while the height or thickness of the TIR element body (as measured from the peak to the mating surface of the substrate) was about 2 mils. Line1510provides a reference for designing a TIR element and indicates the intensity of light received by a light-receiving surface of a solar cell with no optical enhancement film and no TIR elements provided, which is the cosine function over the range of angles considered. The plotted line1520shows the ray intensity received by the same PV light-receiving surface when a PV enhancement film with sawtooth (or two-faceted) TIR structures (such as shown inFIG. 4andFIG. 14) are positioned over or adjacent the light-receiving surface.

For plot1520, the light-receiving surface (such as surface1411) was considered to have 100 percent reflection, which is not the case for PV devices but is useful for determining the functionality of a TIR structure at trapping reflected rays. As shown with line1520, the TIR rays or redirected rays reflected from the light-receiving surface enhance the intensity of the light-receiving surface over the conventional, uncovered PV device. Use of the TIR structure with a solar cell can be seen to significantly enhance intensity when light is received at incidence angles greater than 20 degrees and less than −20 degrees (with a little loss or decrease typically occurring in the central region due to the approximately 4 percent Fresnel reflection losses associated with rays entering the TIR structure). Calculations show that the average intensity of rays with the use of the TIR structure is 0.937 while the reference intensity without a PV enhancement film is 0.699. Hence, an improvement or enhancement gain of over 30 percent (e.g., about 34 percent) is achieved with this TIR structure design.

Of course, a typical solar cell or PV device will not have 100 percent reflection from the light-receiving surface as this would not generate electricity.FIG. 16illustrates a graph1600similar to that shown inFIG. 15for the same TIR structure but with a light-receiving surface with 50 percent reflection. Reference intensity is shown with line1610for the surface with no TIR structures while line1620shows intensity achieved with reflected light being captured or trapped by TIR and redirected back to the light-receiving surface (such as surface1411the facets/sides1414,1416of TIR structure1410). Intensity is significantly increased in the ranges of +/−20 degrees to +/−50 degrees by this TIR structure, with calculations showing an overall gain of at least about 5 percent to 0.735 over an uncovered PV light-receiving surface. Similar modeling at 75 percent reflection from the light-receiving surface showed an increase in intensity of about 15 percent with use of a TIR structure.

FIG. 17illustrates a ray tracing1700for one embodiment of a PV enhancement film1710utilizing a sawtooth arrangement of linear or elongated, two-sided TIR elements1712,1720,1730(with only 3 shown for simplicity whereas a typical PV enhancement film will include numerous TIR structures across one surface). InFIG. 17, the film1710is shown without a substrate at the base of the elements1712,1720,1730(e.g., a film of plastic, glass, or ceramic or the like) for ease of illustration, and the ray tracing assumed that the light-receiving surface at the base of the elements1712,1720,1730had 95 percent reflection. The rays are shown as having an angle of incidence of about −60 to −70 degrees, and it at such-larger angles of incidence where the effects of refraction may become more important.

Specifically, the ray tracing1700shows that received or originally-incident sunlight or rays1702may strike one a first facet/side1714of a TIR element1712(such as at an angle of incidence larger than about +/−60 degrees or the like) and enter the TIR element1714where it may be deflected downward to the light-receiving surface1718. Some of the light/rays though may pass through the second facet/side1716as shown at1704to strike an adjacent TIR element1720upon facet/side1722. Again, some of the light may be directed with originally incident rays1702striking facet/side1722onto light-receiving surface1728. Other portions may pass through through the second facet/side1724to strike facet/side1732of the next TIR element1730, where it again may be directed to the light-receiving surface1738with a portion of the captured/trapped light1702or pass through second facet/side1734. Light reflected from the surface(s)1718,1728,1738likewise may be directed to adjacent TIR elements1712,1720, and/or1730where it may pass through or at least in part be directed to the light-receiving surfaces1718,1728,1738. In this manner, the TIR elements1712,1720,1730use refraction to recapture reflected rays or transmitted rays to increase the efficiency by directing portions of originally-incident but not absorbed light onto the light-receiving surface (e.g., a surface of a solar cell or the like for absorption). This refractive collection or trapping of light may be considered additive to the overall efficiency gain provided by use of TIR elements (e.g., added to the increased intensity shown in prior figures). In other words, rays reflected and escaping one TIR element may be captured by adjacent structures where they can be again directed to the light-receiving surface.

FIG. 18illustrates a graph1800of light intensity as a function of angle of incidence of light upon a light-receiving surface (such as solar cell position underneath the base of the TIR elements1712,1720,1730). In this modeling/evaluation, the TIR structures were elongated or linear body structures with a two-sided (or triangular) cross section as shown inFIG. 17with a base width or pitch of about 10 mils and a height (or thickness) of about 7 mils.FIG. 18shows a reference or baseline intensity with line1810of a light-receiving surface without a PV enhancement film of TIR structures, and line1820illustrates light intensity upon this same surface (such as surfaces adjacent the bases1718,1728,1738) after positioning a PV enhancement film with TIR structures (such as film1710with structures1712,1720,1730). The intensity graph1800is considering intensity contributions due to refraction effects/capturing, and it shows that the TIR structures of a PV enhancement film may be used to significantly increase intensities at highly oblique angles where losses are often highest for a conventional solar cell (e.g., cells in a solar array with no tracking). Specifically, peak intensity gains are seen at angles greater than about +/−40 degrees (with a peak from about +/−60 to 70 degrees). As shown inFIG. 17, the intensity is beneficially increased for angles beyond 60 degrees. Note, in some applications a small decrease in the center portions between +/−40 degrees (as shown for this TIR structure) might be acceptable in order to achieve the increase at around 60 degrees of ray incidence.

A code or pseudocode was used by the inventors in modeling and/or designing the TIR structures/elements for embodiments of PV enhancement films in accordance with the invention is provided in a program listing after this detailed description, e.g., see, U.S. Pat. No. 7,904,871, which is incorporated herein by reference, for code listings, and it is believed that this code/program listing will be useful to those skill in the art in selecting a desirable TIR element for use with a variety of solar cells and solar arrays. The computer code was used in part to calculate the curves provided in the attached figures to determine effectiveness of TIR structures in increasing intensity upon a light-receiving surface over ranges of angles of incidence for received light. In use, after the parameters are read in off a user menu, the PV ray tracing routine is called. The computer program that is used to design and evaluate structures is a non-sequential ray tracing program designed to investigate optical structures for PV output power enhancement. The user enters values on a menu that are to be investigated, and these values such as type of structure (e.g., sawtooth, sinusoidal, cylindrical, and so on) and values for thickness, period, amplitude, and radius (if and as applicable). Deep inside the subroutine, the Fresnel reflection and transmissions are calculated in order to find the final intensity of rays striking the PV surface. The PV trace routine is called and is given in the included code/pseudocode.

The PV trace routine or program will give the user the best values found in the range of search for the TIR structure evaluated. These best values are entered into the data menu and rays are traced to evaluate the structure. Typically, 1000 rays are traced for every 2 degrees of angle between the limits of −80 degrees to +80 degrees, and the results plotted as shown in some of the above figures. To examine the rays and how they are refracted and reflected in the structures a small number of rays, e.g. 100 rays, might be used at a specific angle of interest as shown inFIG. 17.

The inventors also modeled the PV enhancement film732shown inFIG. 7. Ray tracings (not shown) indicated a significant portion of reflected light from the PV or light-receiving surface725was directed back onto the surface725for second, third, and additional chances for absorption.FIG. 19illustrates a graph1900showing with line1910reference light intensity relative to angle of incidence on the surface725prior to application or installation of the PV enhancement film730in the assembly700. Line1920illustrates increased intensity across the entire range of angles of incidence for the received light for the assembly700after application of the PV enhancement film730. In this modeling, the TIR structures734had base widths of 10 mils, a thickness or height of 2 mils (as measured from the substrate732, and effects of the substrate732were neglected for modeling purposes), and each structure had a wall or light-receiving/trapping facet or side having a 7 micron radius (in its arcuate cross section formed by a plane orthogonal to the longitudinal axis of the elongated body of the TIR structure). The average intensity with the film was found to be 0.875 while without the film the average intensity was 0.699, which represents an increase of about 25 percent (with a highly or perfectly reflective surface725, and typical PV devices likely would see smaller improvements in intensity and corresponding efficiencies).

With the above teaching in mind, one skilled in the art will readily be able to expand the concepts to arrive at numerous additional PV enhancement film and TIR structure designs to provide a particular optical effect (e.g., particular light trapping for a planned implementation or use). For example,FIG. 20illustrates a solar array assembly2000that includes a solar array2010including a number of solar cells2012,2014,2016. The solar array2010(or the solar cells2012,2014,2016) has a light-receiving surface2020that generally would be positioned to be directed toward or facing the Sun to receive sunlight when the assembly is in use to generate electricity from available solar energy. As discussed above, the design of the solar cells2012,2014,2016will typically result in the light-receiving surface(s)2020reflecting a percentage of the sunlight that strikes the surface2020, with the percentage of reflected or lost (not absorbed) light varying with the cell design and also upon the angle of incidence of the sunlight on the surface2020.

To enhance light capture, the assembly2000includes a PV enhancement film2030that is applied over the solar cells2012,2014,2016of the solar array2010. The film2030includes a substrate or sheet2032of clear plastic, glass, or ceramic that is substantially transparent to light (e.g., highly transmissive) and includes a planar surface that is positioned adjacent and/or abutting light-receiving surface2020. Upon an opposite side of the substrate2032, a plurality of TIR elements2034are provided, and the elements2034have elongated bodies extending into the plane of the page of the drawing (e.g.,FIG. 20is an end view of film2030) with the cross sectional shape of the bodies defined by a light-receiving wall or facet/side2035. The surface2035in this embodiment is a sine wave (or is sinusoidal) with peaks and valleys.

Modeling of an embodiment of the assembly2000provided the graph2100ofFIG. 21of light intensity as a function of angle of incidence. The line2110models light intensity on the solar array2010(or the light-receiving surface2020) without the film2030, and line2120graphs the light intensity of the light-receiving surface2020of the array2010(or individual cells2012,2014,2016) when the film2030is included in the array2000as shown inFIG. 20. To facilitate modeling, the surface2020was assumed to be a mirror with 100 percent reflection, and the TIR structures2034were assumed to have base widths or pitch of about 10 mils and radius/height of about 7 mils. The average intensity as shown by line2120with the film2030was found to be 0.829 as compared to a 0.699 reference cosine average intensity without the film2030, representing an increase of about 18 percent with an increase seen across the entire range of incidence angles.

FIG. 22illustrates a solar cell assembly2200in accordance with another embodiment of the invention. In this embodiment, the assembly2200includes a solar cell or other PV device2210with a light-receiving surface/layer2214(e.g., a Si wafer with a front contact and AR coating and/or other layers such as a protective glass layer). Over the light-receiving surface2214of the cell2210, a PV enhancement film2230is provided (e.g., applied by adhesive (not shown) or other methods to the cell2210) with a substrate2234having a planar surface abutting or proximate to the light-receiving surface2214. This embodiment may be thought of as a cusps-up embodiment, as each TIR structure2232in the film2230is defined by an arcuate side/facet2236, which has a radius but is downward curved (e.g., generally U-shaped) rather than being upward curved as shown inFIG. 7. In one modeled embodiment, each facet or side2236had a radius of about 7 mils and a width/pitch (as measured between peaks of the light-receiving surface2236of film2230) of about 10 mils. When a light intensity was calculated for one embodiment of the film2230, it was found that the average intensity was about 0.820 while reference cosine average intensity was 0.689 (for a 95 percent reflective surface2214), for a gain of about 19 percent. In another embodiment, the TIR structures had a pitch of 10 mils, a thickness at the peaks of 3 mils (as measured to include the substrate thickness), and cusp to PV material or light-receiving surface distance of 1 mil. In this embodiment, average intensity achieved was better at 0.937, which represents a gain (over no film) of about 35 percent.

Hence, it will be understood that the particular configuration of the TIR structures may be varied widely to achieve TIR/refraction-based trapping of light and to provide improved efficiency for a solar cell or solar array of cells. The particular TIR element design used may depend upon a number of factors including the material used for the film, manufacturing issues such as costs, and planned use (e.g., for a tracking or non-tracking array, to enhance light trapping at particular values of angles of incidence, and so on).

In many PV enhancement films, it may be useful to use a single TIR structure or element design. This may facilitate manufacturing and provide a consistent optical enhancement or light trapping level across the surface area of the film. However, the inventors recognize that there may be a need or desire to use two or more TIR structures (or TIR element designs) on a single PV film or in an assembly of PV films (e.g., films with differing TIR elements may be used together on a single solar array or cell to achieve a desired light-trapping effect). For example, a PV enhancement film may be provided with a sawtooth pattern of TIR elements on one side, and the TIR elements may have the same or differing pitches/base widths and/or the same or differing heights/body thicknesses to practice the invention.

In one film embodiment, the film includes a sawtooth pattern of TIR structures with a number of TIR structures of a first thickness and a number of TIR structures with a second thickness that differs from the first thickness (but with the same pitch in this case while other embodiments may differ the pitch for the two TIR structure designs). The two TIR structure embodiments may be alternated on the film or one TIR structure thickness may be provided for a first set of TIR structures and then the other TIR structure thickness may be provided for a second set of TIR structures and so on in this pattern (e.g., 10 TIR structures of the first thickness and then 10 TIR structures of the second thickness or another alternating pattern). In this manner, two light intensity or light-trapping characteristic curves may (or TIR structure functionalities) may be blended within a single PV enhancement film (or two or more films arranged upon a solar array to provide the differing TIR structures). For example, sheets or films each containing a particular TIR structure arrangement may be laid upon different portions of a solar panel of PV cells. Each location would have the optical response characteristics associated with the overlying PV enhancement film and its TIR structures. The overall effect from each location to the output of the panel or array would be an average response that may be desired by a solar array designer/user. The customer or user of the PV enhancement films could pick and choose the PV enhancement films based on their optical characteristics (e.g., in what incidence angle ranges do they provide better performance and so on) and install (in a retrofit example) or provide during manufacture the films across the PV panel or array to get the optical response they desire. Of course, three or more TIR structure designs may be used together to enhance the efficiency of a solar panel/array or a solar cell and fine tune a PV response.

FIG. 23illustrates schematically an end view of a solar array (or PV device) assembly2300that makes use of the concept of two or more TIR structure designs being included in a single solar array assembly or even a single PV enhancement film. As shown, the solar array2310, which typically would be formed with a plurality of solar cells, has a light receiving surface/layer2312that is positioned in use to receiving incident sunlight. To trap light reflected or lost from surface2312, the assembly2300includes a PV enhancement film2330(e.g., a relatively thin sheet of transparent plastic, glass, ceramic, or the like) that is positioned to at least partially cover the light-receiving surface2312(e.g., front surfaces of solar cells or other portions of PV structures). Instead of a single TIR structure design, the film2330includes two TIR structure arrangements that are alternated across the surface of the film2330(whereas other embodiments may include two or more of one design and then alternate with the second (or more) design).

The film2330includes a substrate or film2332of substantially transparent material, e.g., with a planar surface for abutting or being positioned proximate to light-receiving surface2312. The film2330further includes a plurality of TIR structures upon the substrate2332with alternating configurations. As shown, a first configuration is represented by TIR structure2340that includes first and second facets2342,2344(e.g., has a triangular cross section), and a second configuration is represented by TIR structure2350that includes first and second facets2352,2354(e.g., has a triangular cross section). In this embodiment, the TIR structures2340and2350have the same base size or pitch but differing heights/thicknesses to provide differing optical characteristics (e.g., to achieve differing reflectivity or TIR effects at varying angles of incidence of sunlight upon the solar array2310). These TIR configurations are alternated across the width or length of the light-receiving surface of the film2330. While sawtooth designs are shown inFIG. 23, it will be understood that other TIR structures may be mixed and/or alternated such as structures with 3 or more facets (e.g., to provide a triangular cross section, a pyramid cross section with three, four, or more facets), arcuate or cylindrical structures, sinusoidal structures, inversed curve (or cusp-up) designs, and so on.

To evaluate the film2330ofFIG. 23, the pitches (or base widths) of the TIR structures were set at 10 mils while the height or thickness of the first TIR structure2340was set at 3 mils and the height or thickness of the second TIR structure2350was set at 4 mils.FIG. 24illustrates a plot or graph2400of light intensity as a function of angle of incidence on the light-receiving surface2312(which was assumed to be 95 percent reflective or a mirror in this test run). Reference cosine average intensity is shown with line2410without use of the film2330, and average intensity at the surface2312with use of the alternating sawtooth PV enhancement film2330is shown with line2420. When a film with only 3 mil thick TIR structures was modeled using the included TIR element evaluation or ray tracing routine, there was a relatively large gap in achieved gain in the smaller values of angle of incidence. But, when a film with only 4 mil thick TIR structures was similarly modeled, there was relatively high gain in these same ranges of values of the incidence angle (e.g., −18 degrees to 18 degrees or the like). Then, when the film2330ofFIG. 23was modeled with alternating thicknesses of 3 and 4 mils was tested as is shown inFIG. 24, it was found that light intensity was enhanced more effectively across the range of incidence angles. The average intensity was found to be 0.901 with the film as compared to 0.689 without, for a gain of about 31 percent (but, of course, when reflection is much lower than 95 percent the gain or enhancement achieved will be lower).

The inventors recognize that many other cross sectional and overall shapes for the TIR elements may be useful to practice the invention, and many of these configurations are believed to be considered within the breadth of this description when considered alone or in combination with the attached figures. For example,FIG. 6illustrates use of linear, three-sided or faceted TIR element614in the PV enhancement film610. These may be considered to have pyramid cross sections with three sides. The TIR elements614in some preferred embodiments may be modified to include 4 sides/facets such that the two lower sides of the TIR element are angled inward from the substrate612and the upper sides/facets may be angled inward at a sharper angle to meet at a point/apex. In other embodiments, five or more facets may be included in the cross section of the linear or elongated TIR elements614. Likewise, such 3, 4, or more sided TIR elements may be used in the sawtooth PV enhancement film2330shown inFIG. 23with varying designs being alternated (two, three, or more cross sectional shapes may be provided in a repeating pattern or provided in groups that repeat once, twice, or more times across the surface of the film2330). Further, the inventors understand that PV enhancement films shown inFIGS. 8-11may be modified to include pyramid shaped TIR elements (in place of the cone or frustoconical shaped structures and dome structures or to supplement such pyramid-shaped TIR elements). These standalone pyramid TIR elements may be three, four, or more sided pyramids in which the sides meet at a point (e.g., with each side mating with the substrate at a variety of angles such as 30 to 70 degrees with 45 to 60 degrees being useful in some embodiments) or meeting at a peak surface, which may be planar (e.g., a flat top such that the shape is a truncated pyramid), domed/arched, or another configuration facilitating manufacturing and/or capture of received sunlight.

It may also be useful to further discuss the decision of whether to provide TIR elements that are pyramids and/or three-dimensional structures or that are linear triangular cross section structures. For a perfect orientation of linear triangular structures (TIR structures) to the seasonal azimuth of the Sun, the direction of the linear structures would be in a perfect North to South orientation, and the panel would be placed in a perfect orientation East and West with the panel facing the Sun at mid day perfectly with both axis points parallel to the pathway of the Sun. The above placement/use, however, can typically only be accomplished by mounting panels exactly to the azimuth of the sun in the East to West orientation. However, this is not likely or often practical, as most rooftops are not conducive to this and rather have off-angles in most cases. In addition, even if this were possible (with mounting brackets, by design, or with luck), one would still need to adjust for the seasonal azimuth to the sun to compensate for the 42-degree angular difference from summer to winter.

The testing procedure and software used to model PV enhancement films allowed the additional efficiencies obtained by using linear TIR structures to be measured and modeled in a linear diagram with triangular cross section structures (e.g., in order to observe the individual angular effects and resulting TIR with “ideal” placement), and, hence, some of the initial designs and prototypes utilized two-faceted TIR elements. Given ideal circumstances (e.g., perfect placement), the results would be measureable with these triangular structures and results documented appropriately. However, since ideal placement in the field or home use is unlikely, a three-dimensional structure such as a pyramid is believed by the inventors to provide performance enhancement at off-angles in the direction perpendicular to the linear structure (e.g., a three-faceted pyramid, a four or more sided structure, or similar cross section may be preferred in many applications). Overall, performance enhancement characteristics in non-perfect installations (most installations) may be as much as double or more using pyramidal or three-dimensional (non-linear or linear or 4 or more sided) structures. Typical placement of panels (non-ideal placement) provides not only normal cosine fall off and decreased efficiency from normal sunrise to sunset but also non-perfect placement to the seasonal azimuth of the Sun resulting in additional cosine fall off and resulting reflective losses. Since a pyramidal structure having appropriate benefiting angles in several directions increases TIR and decreases cosine fall off from several angles, overall efficiencies are improved even more than a control model with perfect placement to the Sun. In other words, a non-perfectly placed panel may achieve 10% efficiency overall without the film yet may achieve 18% or more with the pyramidal film, while only 14% may be achieved with linear structures because of the incident angles to the structures.

Numerous methods of manufacturing may be used to provide the PV enhancement films (and apply these films to existing or being fabricated cells, PV devices, and/or solar arrays). For example, various base films may be used as carriers, and the carrier film itself may or may not have photovoltaic material already applied to the film. Base films may be PET, acrylic, OPP, Polycarbonate, polyethylene (high or low density) or even thin glass. The TIR structures may be engraved into a metal, glass, ceramic, rubber, photopolymer or plastic cylinder with diamond tooling, or by a photo-polymeric exposure system, or even laser engraved. The structures may be placed into the film with a combination of heat and pressure with an embossing system in a roll form, or with a hot die stamp and platen directly onto the film itself. Conversely, they may also be cast with UV cured liquid or e-beam, or any type of energy cured polymer or solvent based polymer in roll or sheet form. One preferred method of manufacture may be electron beam casting using polymers that are engineered for durability in the sun.

Many of the above examples and evaluations were limited to a two-dimensional analysis or ray tracing of incident light. In other words, the results in the program take into account a linear structure running in a North-South direction, with the Sun rising in the East and setting in the West and with the collector optimized for the seasonality of the Sun. Therefore, it is believed that implementing the TIR structures as nonlinear, 3-dimensional shapes such as pyramids, cones, domes, frustoconical shapes, and the like may provide even better results and potentially increase the effectiveness in a real life applications exponentially. Keeping this in mind, overall increases in efficiency may go up to more than 100 percent in many cases depending upon the placement of the solar panels or PV devices with the PV enhancement films (e.g., which may be determined by roof shape not based upon optimum angular placement in residential settings and some commercial applications).

In brief, the PV enhancement films provide structures over a solar cell, a solar array, a PV film, or combined with PV film or materials, and the TIR structures are adapted to purposely create total internal reflection. The PV enhancement films (or at least the TIR structures) are made of glass, plastic, ceramics, or energy cured polymers that are substantially transparent (e.g., transmit a large portion of received light). The TIR structures may be nearly any size or thickness, but, in practice due to economic realities, manufacturing challenges, and other reasons, the TIR structures (and the films) often will be under about 100 mils in thickness and routinely under about 5 mils. Some embodiments of the PV enhancement films include elongated or linear TIR structures with two, three, or more straight (or near straight) facet or sides angling inward from the substrate of the film at 10 to 60 degrees. These structures may be saw tooth shapes (when viewed in cross or on end) with 50 degree (45 degrees may be ideal for directly overhead sun) to under 20 degree inwardly-angled sidewalls. In other embodiments, PV enhancement films may include 3D or non-elongated TIR structures that can be 3-sided to a sharp point, be hexagonal shapes to a sharp point, may be cone shaped structures 10 to 60 degrees sidewalls with a point or a flat, planar top, may be circular in cross section to form a series of domes on the PV film surface, or have other shapes to provide TIR effects in a 3D context. It should be noted that the TIR structures, including the linear lenticular-like structures with regular Pi or round radii cross sections designed to go over the top of the PV materials, do not act to “focus” the received or incident light but act to trap reflected light coming off of the covered solar cell or light-receiving surface (e.g., the lenticules of such a PV enhancement film are truncated and appear to be parts of “circles” from a side view and are not configured for focusing received light onto the solar cell). The 3D TIR structures may be dome shaped or “fly's eye” structures. Again, the TIR structures are not designed to focus light (and do not work like regular lenses), but, rather, the TIR domes sit directly on the PV materials (or are the base film for the PV materials) and act to provide TIR trapping of reflected light from the PV materials. A normal lens would have to have a height-to-width ratio of about 1.5 or 2 to 1 H/W to create a focus in a linear or round lens. In contrast, the described TIR structures almost have no height (e.g., are very thin in most cases) and may be thought of as truncated “circles” or thin hemispheres sitting or positioned upon the light-receiving surface of the PV material or of the solar cell(s).

One way to understand some of the concepts of this invention is to understand that a certain percentage of rays that enter through the microstructures (e.g., TIR elements or structures) and hit the film substrate and then the PV material (or light-receiving surface of a solar cell/array) will always be lost. This is due to the relationship of the exiting angles and the point of impact of the wall and those angles (e.g., reflect in directions such that they strike the sides or facets of the TIR structures/elements at angles greater than 42 degrees). It is important to understand that the percentage of deflected rays from PV materials is much greater when light from the Sun in relationship to the panel (which includes the PV materials such as within solar cells) is at a greater angle, which leads to greater deflection and less efficiency, and this occurs typically when the Sun is not at perfect angles to the collector (e.g., not directly overhead at noon or the like). However, a great many of the unabsorbed rays that are deflected from the PV film will try unsuccessfully to exit the microstructures and will be deflected through TIR one or more times (e.g., to a theoretical but nearly impossible infinite number of times), and this TIR functionality of the TIR elements of the invention creates multiple chances and multiple possibilities (and practical differences in angles at every “strike”). Overall, the TIR structures provide a significant mathematical increase in probability for absorption. For instance, operation of a solar array may experience 50 percent of the rays being lost due to cosine fall off or other structural deflections during the daytime as the Sun moves across the sky. But, with the use of the PV enhancement films designed in accordance with one or more embodiments of the invention with one or more TIR structure configuration, most of the deflections are eligible for TIR deflection back to the PV materials (or light-receiving surfaces of a solar array or solar cell or PV device).

The following formulas may be used, with actual data from PV materials for input, to test individual PV enhancement films and/or PV assemblies that include such films and TIR structures. A possible example is as follows:

Z=newly absorbed rays from TIR (20% of X)

S=original efficiency (100%−70%=30% and then (0.30)(0.20)=0.06 or 6%)

More importantly, the above was drawn from the following formula, each individual range below in angles represents an efficiency gain at each of the angles including cosine falloff as a result of the following angles times 2 (covering 140 degrees) as a result of a positive angle or a negative angle.

The above represents approximately 12 hours of daylight or sunshine. Negative numbers represent morning and positive numbers represent afternoon. Positive and negative numbers will yield the same data. For purposes of formula, each set of angles will count twice (one for negative and one for positive). Currently, this formula does not take into account angles resulting from other than ideal panel placement in a north south seasonal azimuth. The reason for this lies in the existing program, and the method of ray racing the program in a linear way and in two dimensions instead of three dimensions. This can be addressed later in future program versions. In other words, it is important to note that in these conditions further mathematical efficiency improvements would be found from this invention. Additionally, linear TIR structures may not yield the best results, and this is why several different TIR structures are and PV enhancement films are shown in the figures with non-linear or non-elongated TIR structures.

Therefore, to find the values of each value (I-O) use, V=Value (indicating total value) times 2 (not squared). For example: Total value of I=value of I×2, which takes into account the morning and evening values. For the purpose of this modeling, the rays being deflected in the ray tracing program striking the strips of absorbers will simulate absorption of the ray, when in fact that ray may be deflected again by the PV material, and then be sent back again by the microstructure. Since the inventors found it difficult to perform this rather subjective experiment with the ray tracing program, the following procedure was used to evaluate TIR structures and PV enhancement films:

Baseline

1. 50% of the “space” between the measurements of the proposed (before placing the structures) structures has 10 separate strips equating to 5% each of the total space as absorbers, and the corresponding remainder are mirrors.

2. Rays are then traced at each value (average value) in each category by changing the incoming ray angles in the programs.

3. Absorbed rays are then recorded with the same input data

Micro Structures Addition

1. Repeat the above, only with the structures.

2. Measure the values using the structures, and calculate the increased absorption.

3. Calculate the absorption by value (angle)

4. Calculating the theoretical addition of the addition of variance in the “Y” axis describing efficiency increases in normally placed field application (imperfect placement).

As discussed at the beginning of this detailed description, the TIR structures may be configured to provide a modification or even an optimization of a path length of incident rays on a PV element or device, and the PV enhancement films may be thought of as including absorption enhancement structures (which provide path length enhancement and also TIR capturing of reflected rays). One of the ways to increase the efficiency of a PV cell output is to increase the path length of photons traveling in the PV material. Such a path length increase improves the chances of absorption and, thus, the conversion efficiency of sunlight power into electrical output power for a PV device or solar power assembly that includes PV enhancement films with properly designed absorption enhancement structures or elements.

The condition of greatest intensity of sunlight striking a surface occurs when the surface (e.g., the light receiving surface of a PV device or of PV material) is perpendicular to the direction of sunlight because the intensity falls off from this point as the cosine of the angle of the incident rays. Rays falling on a PV material perpendicular to the PV light-receiving surface pass through the material along the direction of the shortest path (e.g., have an optical path length equal to about the thickness of the PV material). Manufacturers of PV devices such as solar panels of cells often apply a mirror surface on the back surface of the PV material (opposite the light receiving surface) in an attempt to get a second pass/chance for absorption (and, in effect, obtain some additional path length), but this second pass still occurs at the shortest (or a relatively short) path length direction as the rays are returned by the mirror surface along the mirror reversed path. A longer path length occurs for rays entering the PV material at an angle, but, due to the cosine fall off in intensity, the efficiency increase in absorption due to these longer path lengths is significantly reduced by the cosine fall off.

One aspect of embodiments of the present invention is to provide PV enhancement films with absorption enhancement structures adapted to increase path lengths of rays traveling in the PV material of a PV device (such as a solar panel or array of solar cells) in order to get increased output from light falling on or incident upon the PV collection system (e.g., to better convert incident light on light receiving surfaces of the PV material into electricity). This aspect or feature is achieved via two aspects of the specially designed optical structures provided on the PV enhancement film. One feature is that the angle of rays from the optical or light receiving surface of the absorption enhancement structures refracts rays upon the light receiving or entry surface of the PV device (e.g., a solar cell, a PV cell, or the like with PV material) such that the rays travel in longer paths than they normally would in the PV material without inclusion of the film and its absorption enhancement/TIR structures. The second feature is the property of reflecting back rays that normally would escape from the system or device after not being absorbed by the PV material by using TIR. In practice, both path length increase and TIR redirection are accomplished by using the absorption enhancement structures described herein, which are typically computer-optimized, and provided on an outward facing, light-receiving surface of a PV enhancement film.

FIG. 27illustrates a computer system or computer network2700adapted for supporting optimization of PV enhancement film by, in part, performing optimization processes for absorption enhancement structures including performing ray tracing over a range of incidence angles for one or more structure configuration/design, determining path lengths and path length ratios that compare use of a PV enhancement film with a PV device without such film, and determining if improvements are achieved to identify an “optimized” structure for a particular PV device. The system2700includes an optimization computing device2710that may take the form of nearly any computer or computing device such as a personal computer with one or more processors or CPUs2714. The number of calculations that are performed by the device2710may number in the many millions to billions for each structure being tested/modeled, and, hence, it is desirable for the processor2714to be a relatively high speed and high capacity processor (and/or the computer2710may include two or more cores/CPUs2714to this end). The computing device2710uses the CPU2714to manage I/O devices2718such as keyboard, a mouse, a touch screen, voice recognition software, and other user input/output devices. The CPU2714also manages operation of a monitor2720, which may have a GUI2726to facilitate user data entry such as entry of the optimization input parameters2742, and manages memory2740, which may be local or remote but accessible (in a wired or wireless manner) by the CPU2714to perform optimization processing.

The optimization computing device2710uses the CPU/cores2714to run a structure optimization module (or PV enhancement film optimizer engine or the like)2730that typically is provided as code in one or more programming languages stored or accessible in memory2740or other computer readable medium that is configured to cause the computing device2710(or CPU2714) to perform the optimization functions described herein (such as the method2800shown inFIG. 28). The optimization module2730may run or call an optical enhancer2734to perform numerous functions such as determining path lengths and/or path length ratios, determining when improvements are provided over prior ratios, and so on. The module2730may also call or run via CPU2714one or more ray tracing engines2738to provide ray tracings for a PV device with and without addition of one or more PV enhancement film configurations over a range of incidence angles.

Memory or data storage2740is used to store a variety of input information used by the optical enhancer2734and ray tracing engine2738and a variety of output results (intermediary determinations such as path lengths as well as final results such as optimized structures/films for a PV device and path ratio and ray tracing graphs). As shown, the memory2740is used to store optimization input parameters2742(such as parameters defining/describing a PV device and defining a PV enhancement film and its structures to be modeled/tested), ray tracings2744for one or more PV devices and devices with PV enhancement films, path lengths without PV films2746and with PV films2748, path length ratios2752, and optimized structure/film parameters2754(e.g., the structure or PV enhancement film defining parameters or characteristics for a modeled PV enhancement film that provides more significant improvements in path length ratios, for example, and/or for improved intensity over a particular range of incidence angles striking a PV device).

The product or output generated by the structure optimization module2730may be thought of as the transformation of input parameters and/or other modeling data into the optimized structure/film parameters2754and/or graphs (such as path ratio or intensity graphs provided in the attached figures). Such generated output may be transmitted via wired or wireless digital communication links2761to one or more output devices2760. Such devices2760may include digital data storage devices2762such as portable memory devices (USB memory devices and the like, disks, and so on) or other data stores such as tape drives, servers, and the like. The output devices2760may also include one or more printers for printing out graphs or data reports showing the data generated by the module2730run by CPU2714(such as a listing or table including the optimized structure/film parameters2754). Further, the output devices2760may include one or more display devices2766that may be used to display graphs and/or data (such as parameters2754) on a screen to a viewer/user of the devices2760.

FIG. 28shows an optimization process2800that may be implemented by the system2700(such as by computing device2710running optimization module2730to cause the processor(s)2714to perform the steps of process2800). It may be useful to describe the process2800in more general terms and then proceed with several specific examples of its use to model/optimize a PV enhancement film by selecting absorption enhancement structures useful for providing a desired path length ratio (or path length increase relative to a PV device with no film) and/or TIR that combine to provide a desired improvement in intensity (or increased conversion efficiency of the PV device). As shown, the process2800starts at2804such as with selection by a user of a particular PV device to be used with a PV enhancement film. As discussed above, many PV devices will include a protective cover/top (such as a layer of glass or the like) that may be applied to the PV material with adhesive. In other embodiments, the PV enhancement film may be applied directly to the PV material (with adhesive or the like) such as by providing the absorption enhancement structures as part of a glass or other material protective cover/top (e.g., provide the structures in a glass cover layer). The starting step2804may also include selecting a particular shape and/or arrangement of the absorption enhancement structures for use with the film such as by running the process2800for a particular cross sectional shape for elongate structures (such as triangular cross section, elongated structures as shown inFIG. 4) or for individual members as shown inFIG. 8.

At step2810, with reference also toFIG. 27, a user may enter or select optimization run input2742that may be accessed or received by the optimization module2730. The input parameters may include characteristics of the PV device (e.g., PV material, cover plate or top, adhesive, and thicknesses and refractive indices for each) and of the PV enhancement film including for the structures such as their pitch, thicknesses, refractive index, shapes/configurations, and other parameters that may be needed to properly perform ray tracings through a solar cell or PV device assembly including the film. The user may also enter one or more ranges of angles of incidence or sunlight for use in the optimization run (e.g., optimize over plus/minus 80 degrees, plus/minus 40 degrees, or some smaller range that may have been a weakness of another structure design such as plus/minus 10 degrees or plus/minus 20 degrees or the like). At2820, the optimization module2730may act to retrieve additional modeling data2742from memory2740, which may include retrieving default values for PV elements and/or structures, retrieving refractive indices when materials and thicknesses are entered, retrieving default ranges of angles of incidence when these are not entered/set by a user, and the like.

At2826, the method2800continues with performing ray tracing for the PV element defined in steps2810and2820prior to a PV enhancement film being applied. This may be performed by the ray tracing engine2738run by CPU2714over a range of angles of incidence and the product of such data processing may be stored at2744. In step2830, the method2800includes determining a base path length through the PV material at each angle of incidence in the range (or at a subset of such angles of incidence such as performing tracking at each degree, at every other degree, or the like or at fractions of degrees such as by performing a tracking at each 0.5 degrees or the like). These base path lengths are stored at2746in memory2740. The method2800continues at2840with the ray tracing engine2738performing ray tracing for a next absorption enhancement structure (or PV enhancement film with a particular structure configuration defined by user input provided via step2810and/or default information via step2820). At2844, the path lengths are determined for this structure/film such as by optical enhancer2734or tracing engine2738, and these produced path lengths over the range of angles of incidence of concern are stored in memory2740at2748. Again, these path lengths2748represent the achieved or modified path lengths achieved by applying or including a PV enhancement film in PV device or solar cell assembly (such as changing the direction of the received or incident light with an outer or refraction surface of the structures on the PV enhancement film).

At step2850, the optical enhancer2734acts to determine the path length ratios comparing the PV device or solar assembly with the PV enhancement film and without the film (a base device). The ratio may be determined at each angle of incidence or at the same angles of incidence for which the path lengths were calculated at steps2830and2844, with no improvement or change for each angle of incidence being equal to one and an increase in length being shown as a ratio greater than one (e.g., a ratio of 1.1 indicates an increase in path length of 10 percent at the particular angle of incidence). These ratios are stored in memory2740at2752. At2856, the optical enhancer module2734determines whether there was an increase in path length based on these ratios (with an initial comparison being against base or a ratio of one) relative to previously tested/modeled structures or films. If yes, the method2800continues at2860with storing the parameters defining the present structures or PV enhancement film as optimized structure/film parameters2754in memory2740. If no, the enhancer2734determines at2870whether there are additional structures/films to be tested, and, if so, the method2800continues at2840with performing additional ray tracing and path length calculations for a next absorption enhancement structure or film containing such structures.

If there are no additional structures/films to process with optimization module2730, the method2800continues at2878with storing optimized parameters2754(or identifying these previously stored data points as the best results for structure designs based on improvements in path length shown by high ratios over a particular range of angle of incidence). At2880, the structure optimization module2730may further function to generate one or more path ratio graph, which may be transferred at2882to output devices2760for storage in devices2762, output to a printer2764, and/or display on a monitor2766as graph2768(with input and/or produced date such as the ratio values and path length values and the like) for viewing by users of the system2700. The method2800ends at2890.

The method of calculation used to design the above-described surface of a PV enhancement film includes in some embodiments using a computer (as discussed with reference toFIGS. 27 and 28for example) to trace parallel rays arriving at a PV structure or absorption enhancement structure from various angular directions simulating the sun rays incident on the PV structure throughout the day (or over a particular range of angles of incidence). Then, the computer may run one or more software modules to calculate the path length of the rays in the PV material for various angles of incidence. The total path length obtained from this ray trace is compared to the total path length without the optical device in place (e.g., without use of a PV enhancement film in a solar cell assembly or a PV device) to obtain a path length ratio for the film.

Thus, for example at 30 degrees incidence, if the total path length of the rays traced without any enhancement structure adds up to 10 mm and the total path length adds up to 15 mm with the inclusion of an absorption enhancement structure of the invention, the path length ratio at 30 degrees incidence is 1.5 (which represents an increase of 50 percent in optical path length at this angle of incidence for this particular absorption enhancement structure). The ray tracing and path length and ratio calculations are done for each angle of incidence (or a subset sampling of such incidence angles such as using 5 degree increments when the range of angles is −80 degrees to +80 degrees). An average path length ratio may also be calculated for the whole run of angles as well as calculating a peak length ratio, e.g., a PV enhancement film may provide an average path length ratio of 1.3 while a peak length ratio may be 1.5. Optimization may also include determining the ratio particularly in the area of higher sun light intensity (e.g., from about plus/minus 40 degrees and more typically plus/minus 20 degrees) to verify that improvements are obtained in this important region, which as discussed elsewhere may benefit from mixing of two or more structure configurations to achieve a better overall efficiency increase (as well as improved average path length ratio, e.g., in the above example, two absorption enhancement structures may be used within a single PV enhancement film to increase the average path length ratio from 1.3 to 1.4 or 1.5 or more by filling any holes or weak ranges of angles of incidence in the design achieving a ratio of 1.3).

FIG. 29illustrates a ray tracing2900for a particular incidence angle as may be performed by a ray tracing engine (or optimization module) of the invention for a commercial or conventional solar cell or PV device. As shown, the PV device2910includes, from the top down, a protective glass cover2912, PV material2914with its light receiving surface2915, and a reflective backing or mirror element2916. Sunlight or light rays2920are received by the device2910at an incidence angle, θ, such as 20 degrees or the like. In a typical tracing, a large number of rays2920would be traced such as 100 to 500 or more per angle of incidence (or per each angle in a subset traced within a range of incidence angles of interest for optimization), with a much smaller number shown inFIG. 29for clarity and ease of illustration.

The rays2920strike the protective glass cover/top2912and are refracted as shown with rays2922to strike the PV material surface2915at a second angle (or angle of incidence of light or angle of received sunlight upon the PV material2914), β, which may be smaller than the original angle of incidence, θ, such as 10 to 20 degrees when the value is 20 to 30 or the like. Then, the received light2924travels through the PV material2914where it strikes the reflective surface2916(if not absorbed) and is reflected back out of the PV device2910as shown at2930. An enlarged or close up view of this tracing is shown inFIG. 30. This shows more clearly the path length of the rays2924traveling in the PV material2914, andFIG. 30also shows that the optical path is relatively short or direct. Hence, improvements in absorption can be obtained by changing the direction of the rays striking the surface2915of the PV material2914(or to provide a larger incidence angle, β, as measured from an orthogonal plane to the surface2915). Also, as discussed above, TIR may be used to capture or redirect at least a portion of the rays2930prior to their loss from the solar cell or PV device assembly.

InFIGS. 31 and 32, ray tracings3100are shown for a solar cell assembly or PV device3110that includes the PV device2910ofFIG. 29with its protective glass cover2912, PV material2914, and reflective backing2916. Additionally, though, a PV enhancement film3120is included that is applied over the glass cover2912with an adhesive layer3130. In this embodiment, the PV film3120includes a sawtooth pattern of absorption enhancement structures3124on a substrate3128, with the structures3124having a single configuration (e.g., elongated bodies extending the length of the film3120with a triangular cross section as shown, for example, inFIGS. 4 and 5). With the use of the PV enhancement film3120, the incident or received sunlight2920at incidence angle, θ, but are refracted by the facets or refraction/light receiving surface of the structures3124. As a result, the rays3140traveling through the glass cover/layer2912strike or are incident upon the light receiving surface2915of the PV material2914at a second angle or second incidence angle, α, that differs from the base device or device without the PV enhancement film. Typically, this second angle or angle of received sunlight, α, is greater than without of the structures3124(such as a few to many degrees larger than angle, β). The light3144than travels through the PV material2914along a different, longer path as shown with the path length inFIG. 32, which provides a path length ratio that is greater than 1 and that allows the PV material, in use, to more efficiently absorb the rays3144as compared with the rays2922that follow a shorter path through the PV material. Although not clearly shown inFIG. 31 and 32, the structures3124also provide a level of ray capture of light reflected from the surface2915and/or from surface2916back up to the PV enhancement film, with TIR redirecting at least some fraction back to the PV material2914for possible absorption in a second or greater number pass.

Significantly, the ray tracing3100is performed taking into account the presence of the glass2912and also the adhesive3130. This enables the path lengths in the PV material2914to be more accurately determined, which, in turn, allows a better optimization (or selection) of a combination of structures3124(size and/or shape) and adhesive3130for a particular PV device with a known cover2912(or to allow a designer to select from two or more such protective glass covers or tops, with it being understood that cover/top2912may be made of other materials than glass with the tracing simply being adjusted to include the parameters such as thickness and refractive index for the different material).

The components of the PV device assembly3110may be varied to practice the invention with differing covers2912, differing PV materials2914, and, of course, a wide variety of PV enhancement films3120with a variety of configuration for structures3124(as shown in the numerous figures presented herewith). However, it may be useful to further describe at least one configuration or arrangement for a solar cell assembly3110that was modeled using the computer system2700ofFIG. 27. The PV material2914in this example was a thin film amorphous silicon PV layer with an index of 3.44 and a thickness of 11 mils. The cover2912was assumed to be formed of a thickness of 125 mils of glass with an index of 1.5. The adhesive3130was assumed to have a thickness of 2 mils and an index of 1.51. The PV enhancement film3120was formed of a plastic with an index of refraction of 1.49, with elongated sawtooth structures3124of a single triangular cross sectional shape. In the film3120, the pitch/base of each structure3124was 13.333 mils with a height or thickness of about 7 mils while substrate thickness was 4 mils. Also, the ray tracing module acted to trace 470 rays per angle modeled for a single angle of incidence (e.g., about 20 to 25 degrees). The optical enhancer or structure optimization module processed the ray tracings of the assembly3110as well as a base or uncovered PV device and determined that the average path length ratio was 1.283, which represents an increase in path length of 28.3 percent with this configuration of the PV device, adhesive, and PV film including its material, substrate thickness, and absorption enhancement design.

In some cases, as discussed with reference toFIGS. 25 and 26, a PV enhancement film such as film3120may show weaknesses in particularly desirable ranges of incidence angles such as within the prime solar energy collection range of about −20 to about +20 degrees (or up to plus/minus 40 degrees in some cases). When ray tracing and path length calculations are performed for the film3120, the result may be that average length ratio is 1.525 with a peak length ratio up to over more than 3. However, the graph of the path length ratio relative to angle of incidence, such as that shown inFIG. 25, may indicate that there is a weak spot or gap in the usefulness of the film3120in increasing path length such as in the range of −10 to +10 degrees.

Hence, the design process for a PV enhancement film may call for optimizing the path length ratios for a PV enhancement film for a certain desired angular range or spread such as −20 to +20 degrees (as measured from orthogonal for the light receiving surface of the PV material) to increase the efficiency of the PV device. To this end, the assembly3110with the single design of structure3124may provide a gap in this target range of angles (as shown inFIG. 25). The overall angular range for a PV enhancement film can, in some cases, be improved by providing two or more sets of absorption enhancement structures each with differing designs that may be useful for obtaining a better path length (or TIR response) for ranges of angles. By combining, for example, a second structure that addresses the weaknesses of a first structure with the first structure on a single PV enhancement film, a better overall path length ratio may be achieved and/or the conversion efficiency may be increased (e.g., the ratio may not be increased and may even be lower but if it is enhanced in prime real estate such as plus/minus 20 degrees the efficiency can be increased without an overall jump in the path length ratio).

In one exemplary embodiment of mixing structure configurations in a PV enhancement film,FIG. 33shows a mixed sawtooth pattern of two absorption enhancement structures3324,3328in a PV enhancement film3320that also includes a substrate3330. The PV enhancement film3320is mounted onto a PV device2910(such as that described with reference toFIGS. 29-32) with a layer of adhesive3340applied to the cover glass2912to form a solar cell assembly or enhanced PV device3310. In this assembly3320, a first set (or about half of the overall number) of structures3324is provided that have the shape and characteristics described for the film3120ofFIG. 31(e.g., with a pitch of 13.333 mils, a height/thickness of 7 mils with two facets or sides3325extending along the length of the structure3324and meeting at a point to define a triangular cross section). A second set (or about half) of structures3328is provided that have a different shape such as having the same characteristics such as pitch and index but a differing height/thickness of about 10 mils to provide facets or sides at a differing angle to obtain differing refraction and also differing TIR effects. Typically, these two sets of structures are alternated on the PV enhancement film, but, in some cases, two or more of each design may be grouped together and these groups may be alternated (with the more significant feature being the mixing of two differing structure designs to obtain improved overall results).

FIG. 33shows a ray tracing3300with this dual-structure PV enhancement film3320applied to the PV device2910to provide an assembly3310that is substantially more efficient than the PV device2910. In part, this is because the two structures3324,3328with differing facets/light receiving surfaces3325,3329, respectively, act in conjunction to provide an average length ratio of about 1.2 to about 1.5 or more (or up to about a 20 to 50 percent or more increase in path length on average; whereas, note, when the structure of the first set with a thickness/height of 7 mils is used alone the overall or average length ratio may be nearly the same value but the increase obtained in the −10 to 10 degree range makes the mix of structures highly useful for increasing not just path length but resulting efficiency of the resulting solar cell assembly), which may significantly increase the ability of the PV material of device2910to absorb photons or received solar energy. The curve of the PV path length ratio compared with angle of incidence of the assembly3310may take an appearance similar to that shown inFIG. 26, and, particularly, the addition of or use of the second set of structures3328fills the gap or hole (hole/gap2520of graph2500inFIG. 25) by providing a large improvement of path length in the range of −10 to +10 degrees such that the PV enhancement film3320has very desirable properties in prime solar energy collection ranges of −20 to +20 degrees (or, typically, from about 10 AM to about 2 PM in the northern hemisphere and during much of the year). Additionally, the structures3324,3328provide TIR to reflect at least some of the reflected light from the PV material as can be seen in the tracing3300particularly in the second set of structures3328at this particular angle of incidence.

As will be understood from this detailed description, a number of different types of structures can be considered for optically enhancing the path length in the PV material. In some embodiments, the computer-implemented optimizing program has built-in circular lenticular shapes, both cusp up and cusp down, sinusoidal lenticular shapes, and saw tooth cross section lenticular shapes that can be investigated and used for the absorption enhancement structures of a PV enhancement film and included in an optimization run. In a typical run, a shape will be picked by a user providing input. Then, the parameters appropriate to the structure such as radius, amplitude, thickness, pitch, cusp to structure base spacing, and the like may be entered by the user but, more typically, are varied and traced as described before by the optimization module. An optimization run will try all combinations of the parameters set or chosen by the program user.

In one optimization run with a saw tooth design with one structure configuration, the following parameters were used. Starting at the bottom of the overall PV device and going up, there was a mirror or reflector and PV material of thickness 11 mils and index of refraction 3.44. The PV device also included cover glass of thickness 125 mils and an index 1.5. The PV enhancement film was applied using an adhesive layer of thickness 2 mils and index 1.51, and the film included optical enhancing material with index 1.49. The optimization module or software run by the computer used a ray trace width of 600 mils (e.g., the range over which the structures will be traced) and a starting angle of −80 degrees and a stopping angle of +80 degrees, with a step angle of 5 degrees (e.g., tracing over the range of plus/minus 80 degrees by 5 degree steps). In the optimization, the number of rays traced per angle was 235 while the number of structures traced was 35 to 70 in steps of 1. The thickness of the sawtooth traced was from 3 to 12 mils in steps of 1 mil while the cusp to base spacing was 4 mils (e.g., the substrate of the PV film was 4 mils). The highest average path length ratio identified occurred for the following saw tooth conditions during the optimization, a structure with a pitch or base width of 13.333 mils and a structure height or thickness of 7 mils, and the resulting path length ratio on average was 1.525 with a peak ratio of 3.084. However, a gap such as gap2520shown inFIG. 25was found for this optimized configuration for the range of plus/minus 80 degrees in the range of plus/minus 18 degrees.

Hence, to fill in the values between about −18 to +18 degrees another run was made limiting the optimization angle values used to be between −20 to +20 in steps of 5 degrees (note, the peak ratio of the 7 mil high structures was outside plus/minus 20 degrees). With this new limiting optimization input (e.g., an incidence angle range of plus/minus 20 degrees as opposed to plus/minus 80 degrees), the optimized thickness found was 10 mils (with a base/pitch again of 13.333 mils and a substrate thickness set at 4 mils). The two optimized results (or absorption enhancement structure configurations or design defining parameters) were combined to produce a PV enhancement film having an alternate sawtooth pattern of structures with alternating thicknesses of 7 and 10 mils (and bases of 13.333 mils and substrate thickness of 4 mils). A ray trace was done from −80 to 80 degrees for this dual-structure PV enhancement film, and the path length ratio plot of the combined structure is similar to that shown inFIG. 26, where we see a substantial increase in path length ratio across the angular range (e.g., an average path length ratio of about 1.526). The included apex angle (between the two facets and defining the shape of the facets or sides or refraction and TIR surfaces of the structures) of the 7 mil thickness sawtooth was 131.544 degrees and of the 10 mil sawtooth 96.026 degrees.

As discussed, the design of the structure(s) for the PV enhancement films of embodiments of the invention may be performed or facilitated by an automatic optimization routine (as shown inFIGS. 27 and 28) that does a ray trace over a range of variables for a range of angles stepping a specified value (for the variable and/or the angles). Each incident angle of rays that is traced by this optimization module is evaluated by the module for the path length ratio increase over the non-optically enhanced surface. The average increase is compared to the best value obtained to date and, if the current value is an improvement, the parameters for the structure/film are saved in memory. At the end of the run of all angles and all structure parameters, the best combination of parameters (or optimized parameters for the structure/film) is recalled and output (e.g., transmitted to a display or other output device).

The above is a substantial portion of the special ray tracing used to calculate items or parameter values used in the design of the optical structure or absorption enhancement structure.

The above examples have stressed the use of the PV enhancement film over a protective glass layer to increase path lengths and/or capture or redirect reflected rays. Although this is useful in retrofit applications or to allow continued use of an existing PV device design, the PV enhancement film may also incorporate the protective glass in its substrate (e.g., replace the glass or other protective cover with a layer of glass that includes the TIR or absorption enhancement structures described herein). For new panel construction, it may be advantageous to create glass panels with optimized structures built into the glass maximizing (or at least improving) the performance of the PV material based upon the characteristics of the PV material and the desired gain in performance at specific angles.

Customizing the thickness and the characteristics of these structures within the glass itself is advantageous and can provide significantly better results for performance enhancement for PV materials (e.g., more than an overlay film as described in some of the above examples of PV enhancement films). This better result is in part because a PV enhancement film designer has more latitude with the creation of the structures and their optimization in the software program. In other words, the likely enhancement created by the overlay embodiments of the PV film necessitates the use of existing parameters of the solar cell or PV device such as the ⅛-inch layer of glass already over the panel or PV material. Allowing the optimization program or module to optimize both TIR and increased path length structures for structures provided on the glass surface or within or as part of the glass cover or top allows for better results relative to a later applied film and a wider parameter of data possibilities. The possible absorption enhancement structures in some embodiments include structures going down toward the level of the PV material (or nearly) and all the way up to the top of the glass (⅛″ thick). These possibilities make for greater possibilities in enhancement, especially for path length enhancement.

Data can be gathered from the desired PV product based upon its reflective and absorption characteristics of the material. Standard poly-silicon may have certain characteristics for reflection at certain angles, and also different absorption characteristics. Path length can be optimized at desired angles with the combination of several different structures (such as an alternating sawtooth pattern or the like) while TIR structures can also be added to the glass for recycling reflected rays (e.g., a sawtooth pattern with two, three, or more structures on or within the glass to provide a desired combined result). In some embodiments, a combination of structures optimized for TIR and path length as a result of the characteristics of the PV materials can be built into the glass, with better overall results as compared with a film overlay because of the advantage of using the thickness of the glass for structure optimization. In some aspects, the concept of using a specially designed glass layer as the film is the same or similar to that described above for a later applied PV enhancement film, but the ability not to have an intervening glass top or cover to start with and all of the thickness to work with (e.g., to include as part of the PV enhancement film or structure) may provide much better optimization of the desired structures in some designs of PV devices such as solar arrays.

The PV enhancement films with absorption enhancement structures may be manufactured in a number of ways to practice the invention. Likewise, the PV enhancement films may be affixed or provided within a PV device such as a solar array or solar cell device in a number of ways, e.g., with adhesive that may be applied to the PV enhancement film using one of a number of techniques. Briefly, the PV enhancement films may be produced using sheet-roll extrusion, using cast film techniques, using extrusion coating embossing, by creating energy-cured cast structures on a carrier film, and other manufacturing methods useful for forming the various absorption enhancement structures taught or suggested herein on a surface of a plastic, ceramic, glass, or the like film or substrate. Many of these film manufacturing processes may utilize a roller such as a chilled embossing roller (or chill roller, embossing roller, or the like) to form a desired pattern or cross sectional shape on a film's surface to create a PV enhancement film, and the following discussion describes techniques for fabricating such embossing rollers to produce the absorption enhancement structures.

In some embodiments, sheet-roll extrusion is used to form the PV enhancement films described herein for application to or use with a solar array/panel, e.g., to form the PV enhancement film114that may take any of the forms described herein. The use of sheet-roll extrusion is well-suited for use in fabricating the PV enhancement films with linear or elongated, side-by-side absorption enhancement structures such as PV enhancement film420with triangular shaped TIR structures, films2330and3320with alternating sawtooth patterns of TIR structures, and the like. PV enhancement films fabricated by sheet-roll extrusion may be further processed by applying an adhesive layer (as shown in some of the attached figures such asFIG. 33) and applied to a PV device. Specifically, sheet-roll extrusion is a process that may be useful for providing good economy, speed, and scalability for the aftermarket product over glass panels and similar solar devices already in the field, manufactured, or designed for fabrication as an add on or later step to improve its operation and/or conversion effectiveness. Benefits of this product include the ability to process thicker materials that are more easily handled by the consumer for application. For example, sheet-roll extrusion is an appropriate fabrication/manufacturing method for absorption enhancement structures and overall film thicknesses between 7 mils ( 7/1000 inches) and ⅜-inch. Target thickness for this product may be 20 mils or 20/1000 inches.

The sheet-roll extrusion process is a film fabrication technique that is not exceptionally fast but is found desirable for forming accurate TIR structures because it is consistent and continual. The extrusion process may start with a selection or design of a feed material for a PV enhancement film such as one or more plastics or polymers in the form of pellets with or without additives such as stabilizers, and the polymer mix is blended in a screw drive mixer or other mixer/blender. At this stage, the desired blend of polymers, additives, UV inhibitors, stabilizers, and the like are added to the mix depending upon the intended usage, e.g., to obtain a desired index of refraction, durability, and so on. The screw drive and mixer blends the polymers and other feed ingredients at a mixing (or extrusion) temperature, e.g., at a mixing temperature in the range of above ambient up to about 350° F. to even up to about 450° F. or higher.

The molten polymers are then fed into a series of rollers including or containing a chilled embossing roller that is pre-engraved with the desired pattern. Particularly, the desired pattern is a pattern that produces a set of the absorption enhancement structures on a surface of a PV enhancement film (e.g., a mirror image useful during rolling contact with a heated polymer sheet or material feed to create the films shown or described herein). In some embodiments, the series or set of rollers may include an engraved roller positioned as the top chilled roller and at least one bottom pressure roller opposite the engraved roller and that may be flat/smooth or polished though it may have a pattern/texture in some cases. As the molten feed material or polymer is “pulled and pushed” through the rollers, the contact with the chilled top and bottom rollers acts to harden the feed material to form a PV enhancement film such as by causing the “freezing” the polymer at the molecular level leaving a mirror imprint of the engraved pattern on the cylinder on a light receiving surface of the PV enhancement film.

In some implementations, extrusion lines are from about 24 inches wide to over 60 inches wide, e.g., the output film may be 24 to 60 inches wide (prior to further cutting/processing to form PV enhancement films for application to solar arrays or cells or other PV devices). Generally, the running speeds of these production lines may be between 15 and 30 feet per minute, depending upon the thickness of the sheet and the type of polymer being used to produce the PV enhancement film. As the material or film comes through the extruder and further cools, the outside edges may be cut with a slitting blade for an accurate cut, and the extruder may include blades or other mechanisms for slitting the sheets or films in several places to make smaller sheets or films as the sheets come through the equipment. The material or PV film continues through the equipment until it reaches a sheet or PV enhancement film stacker that automatically stacks the material in exact and desired sheet stacks and sizes at the end of the line.

One usefull polymer or feed material for use in sheet-roll extrusion (and other fabrication processes) for solar enhancement film is a specialized UV-stabilized blend of polycarbonate, acrylic, fluoropolymers, and the like. Target lifetime of these polymers may be approximately 20 years or more. Since the target thickness of some PV enhancement films or products may be about 20 mils, the general running speed of the extrusion line may be about 25 feet per minute on lines capable of running 50-inch wide films or the like. In some cases, two sheets may be run through the line at once to produce two solar panel cover sheets or PV enhancement films (or a sheet that may be cut into a plurality of PV enhancement films) at once for this application. In this case, panel covers or PV enhancement films/sheet of film products may be made at a rate of 16 covers/sheets per minute for a 24-inch by 36-inch panel or the like. This equates to about 960 panels per hour and over 23,000 in a 24-hour day of production on one line.

In some embodiments, the PV enhancement films described herein are formed as cast films. Cast films (or PV enhancement films with the absorption enhancement structures described in the figures and throughout this document) may be made by extruding a volume of a molten plastic from an overhead extruder wherein the extrusion die is fed from a screw drive or other hopper system starting with polymer pellets or other feed material. The molten plastic is pushed under high pressure through the die, which may be accurately adjusted to produce a molten “web” of continuous plastic. This substrate or sheet of material runs over a chilled embossed roller. In this fabrication technique, the molten plastic cools and solidifies quickly as it is pressed over the chill roll with another roller so that the plastic (or a surface/side of the web/sheet) takes on the shape of the engraved chill roller to form a PV enhancement film with absorption enhancement structures according to an embodiment of the invention.

In another embodiment, PV enhancement films are formed using extrusion coating embossing. This method of manufacture may be particularly desirable for thinner PV enhancement films and/or for base films. For example, extrusion coating embossing may be used to form solar cell assemblies or PV devices in a method that includes directly applying PV materials in flexible film applications, with one example being copper indium gallium di-selenium (CIGS) production and another example being a flexible cadmium telluride PV product. The PV enhancement film formed by this technique may also work as a base film for dye sensitized organic films such as PV products/films available from Konarka Technologies, Inc. and other PV film/product manufacturers and such PV enhancement films could be married to existing flexible PV products to provide a more efficient PV device such as a solar cell or the like.

The extrusion coating embossing process or technique for manufacturing PV enhancement films has some similarities to the roll-embossed sheet product (or sheet-roll extrusion discussed above) with some nuances. In this film fabrication process, a primary carrier film is typically used that may be a PET, an acrylic, an OPP, a fluoropolymer, or the like. For many solar applications, PET film may be a useful choice for producing a PV enhancement film. In this case/example, the PET film starts at the end of the embossing device or machine on a large roll and is fed through the machine to a coating unit that applies a very thin water-based coating or similar coating that aids in the adhesion process for the next step. The PET film or feedstock then goes directly around a chill roller with a pattern in the roll (in this case a pattern useful for creating a set of absorption enhancement structures).

Before the film hits the roller, an extruding device overhead squeezes out a molten polymer (e.g., acrylic, polycarbonate, fluoropolymer, or the like) that comes out in the desired thickness (about 2-3 mils for example) and is applied evenly to the PET film (which is about 0.5 mils to 3 mils thick in some PV enhancement film fabrication embodiments). As the liquid polymer hits the PET film, it comes in contact with the chilled embossing roller and may also be pushed against the chilled roller by a softer roller such as a rubber roller. The liquid polymer takes the pattern of the chilled roller to form the absorption enhancement structures. The PV enhancement film (or sheet with a plurality of such PV enhancement films or film products) continues down the line and is rewound at a roll station at the end of the line after the film cools at least somewhat. The speed of this type of production can be fast at up to 300 feet per minute or more, but, in some embodiments, PV enhancement films of desired quality of reproduction of the solar structures are formed with a running speed of about 75 feet to 100 feet per minute or the like. Per the example above, enough film for 64,000 panels at 24 inches by 36 inches may be manufactured in 24 hours from one production line.

In other embodiments, the manufacture of PV enhancement films includes providing energy cured cast structures on a film. This method of manufacture may be useful as it can provide near perfect structure replication using energy-cured polymers to reproduce the structures on top of a carrier film. In this method, a carrier film, e.g., a film made of PET, polycarbonate, a fluoropolymer, or the like, is used as a base film. The film then goes into a casting device that applies an optically clear, energy-cured polymer to the film at a precise thickness. This film with the coating applied comes in contact with an engraved embossing roller (e.g., a roller embossed with a pattern corresponding to a set of absorption enhancement structures described herein), and the liquid polymer squeezes into the shapes engraved on the roll. While still in contact with the embossed roll, UV or electron beam radiation may be applied to the back of the film. The radiation goes through the film and into the polymer where the shape of the TIR structures is reproduced on the carrier film. Running speeds are between 10 feet and 200 feet per minute depending upon the curing technology. An advantage of using energy cured cast structures on film is that the structure reproduction is perfect or substantially so. One disadvantage is that there are limitations on the size of the structures, and another disadvantage is that the process can be more expensive that the other methods because of the cost of the polymers. There is also a problem with yellowing in the sun for this application. As a result, this manufacturing application or technique may be more useful for prototyping of PV enhancement films and other specific uses.

To facilitate assembly of a PV product such as a solar cell or array with a PV enhancement film applied thereto, manufacture of a PV enhancement film may include applying or providing an adhesive layer to the planar side of the film or the side opposite the PV enhancement structures (which may be formed as described above). For example in a roll sheet application, adhesive application for extruded sheets may be a two-step process. First, the adhesive is extruded onto a silicon release liner, or on a thin PET carrier film or the like, and then rolled up in a large roll. The adhesive process is much like the extrusion coating process, however, with larger drying tunnels heated with hot air, infrared drying or UV curing to allow the adhesive to cure properly. Both water based and solvent-based adhesives will be considered and used for solar application based upon costs and availability/characteristics. Normally adhesive coating lines are quite large (300 feet or more in length) and operate at between 50 and 300 feet per minute.

The second or next step for application to the solar enhancement sheet may be a roll-to-sheet lamination process. In this process, the solar sheets or sheets of PV enhancement films/film products may be loaded into a feeder on a large laminator and then fed through the machine that laminates the rolls directly to the sheets, e.g., at rates of between 50 and 100 feet per minute or the like. The adhesive liner and adhesive is cut as the sheets stack together and the sheets are again stacked automatically at the end of the line to provide PV enhancement sheets or PV enhancement films (e.g., sheets that may use additional processing such as cutting prior to application or PV enhancement films that are ready to apply to a solar array or the like, and, of course, additional shaping or processing may be done in the field or elsewhere to size/shape a film to a receiving surface of a solar or PV device.

In a thin film application, the adhesive may be applied directly to the pre-embossed film, and a liner may be applied at the same time. This can be done in the adhesive application process. For example, instead of applying adhesive directly to a liner or a film carrier, the adhesive may be applied directly to the solar film itself, and the liner may be applied in one process. The completed product is then taken to a “sheeter” or similar device that functions to cut the rolls to a desired width and length in an automated process at up to 75 feet per minute or faster.

To fabricate high quality PV enhancement films with absorption enhancement structures matching a desired pattern (such as one selected/set by the optimization software tool), it is desirable in many cases to form a cylinder that may be used as the embossing roller or chilled roller used in the above processes. Forming the embossing roller or cylinder is performed using engraving of its surfaces, and the engraving process can be accomplished in a variety of ways with several exemplary processes described below.

In one engraving process, a diamond tool with the angles pre-formed in the diamond (e.g., atomically etched or ground to exact angles) is used to engrave a cylinder made of copper, aluminum, steel, nickel, or the like. One preferred method may involve engraving over the nickel plating or engraving the copper and then nickel plating the cylinder/roller surface afterwards. In some cases, the linear structures or elongated TIR structures (or a mirror image of such structures to later be formed on a sheet of plastic or the like) can be formed with a “screw” process. In other cases, though, the engraving method may be to “index” cut the cylinder with a “cut and plunge” method in which one cut is made, the tool is lifted out of the cylinder, moved over exactly or precisely to the next desired location and then plunged back into the cylinder, and such a process is repeated across the width of the cylinder.

Another engraving method is to use a smaller diamond tool that has a certain tool pathway programmed into a lathe computer, and the system memory may store a plurality of such pathways to fabricate each of the TIR structures described herein and the method may include a technician selecting the appropriate pathway to form a desired set of absorption enhancement structures. This pathway allows various angles to be made into the cylinder by cutting several times for one structure.

Another method of engraving may involve using photo emulsion techniques and exposing polymeric metals with exposures. Then, an acid bath may be used to remove the unwanted materials. In this process, three-dimensional structures can be made such as shown inFIGS. 8-11. Another option for engraving the embossing roller surface may be to use lasers to directly engrave the metal cylinder surface using a file from a software program mapping out the TIR structures (or a mirror image of such structures). In this process, the laser blasts away the unwanted metal areas and material may be washed out in a separate process.

While not limiting to the method of fabrication chosen, it may be useful to discuss fabrication costs that may be used in choosing a film fabrication process and/or method of forming the embossing roller or cylinder. Presently, costs for “green rolls” or blank cylinders may vary from about $10,000 (USD) for small rolls to over $30,000 for large rolls. Diamond tools, depending upon their complexity vary from about $1,200 to about $4,000 each. The average tool for solar application is about $2,000. The engraving process per roll has a cost for engraving and nickel-plating of between $10,000 and $30,000. These up-front or capital costs may be recaptured readily, though, as one engraved roll or embossing roller can be used in the PV enhancement film fabrication processes to produce millions of feet of material with the absorption enhancement structures.

Because diamond turning may likely be one method used by the inventors to form PV enhancement films, the following provides a more detailed explanation of how diamond turning can be used to engrave a cylinder for later use as the chilled embossing roller in forming linear or elongated absorption enhancement or TIR structures on a surface of a sheet or web of feed material such as a plastic or polymer feedstock. Linear structures may be engraved around a cylinder that will be used in the manufacturing process as the embossing roller. Engraving these cylinders may be done with a diamond tool on a high quality lathe in a temperature-controlled room. The diamond tool or cutter itself may be controlled or positioned in at least 3 axes on the lathe including: positioning across the width of the cylinder (which is typically spinning on its axis in the lathe during cutting/engraving operations) with a travel arm or the like that supports and positions the tool/cutter tip; positioning the tool/cutter tip in and out (or a depth) relative to the cylinder surface that is being engraved; tilting the tool/cutter tip east-west (or side to side parallel to the cylinder axis or along the travel arm axis); tilting the tool/cutter tip north-south (or forward and backward orthogonal to the cylinder and travel arm axes (which are parallel to each other)); and tilting the tool/cutter tip diagonally relative to the cylinder and travel arm axes.

The desired structure (e.g., mirrored pattern of the plurality of TIR structures to be formed on a plastic sheet) may be engraved with a diamond or tool/cutter tip that has the desired angles and structure in the tool for a single pass operation. In such a cut and plunge operation, a valley or trough between two adjacent TIR structures (or their mirror image structures) may be formed by the tool. In other cases, the engraving is performed with a smaller diamond or tool/cutter tip that cuts the desired shape in small increments, and this technique may be called single point diamond turning. This may involve a small cutter/tool tip making numerous (20 to 100 cuts or more) per structure or structure face/receiving surface with each cut being incrementally deeper and often at differing angles, positions along the travel arm, and so on (see various controls discussed above). In some cases, the structures to be formed/engraved in the cylinder surface may be indexed, wherein one continuous spin produces one “ring” around the cylinder or in a method like a “screw” going across the cylinder by moving the diamond across the cylinder.

Again, axis controls on the lathe may be done with up to 6 axes. The axes may be described as follows: (1) across the cylinder; (2) depth (into the material and back out); (3) left to right turn of the tool; (4) up and down turn of the tool; (5) diagonal turn of the tool; and (6) diamond tool may also “spin.” In many embodiments, the desired coordinates are stored in a data file stored in memory and accessed by a tool/lathe control program run by the engraving system/machine to create a “tool pathway” that becomes the road map for the diamond tool itself, which dictates the exact movements of the travel arm and position/orientation of the tool/cutter and its tips as well as other operating parameter such as speed of the lathe in spinning the cylinder.

In some embodiments, the engraving is done directly into a cylinder having a metal surface (such as a hard copper surface). The engraving into the cylinder is completed and, usually but not always, the cylinder is then plated with nickel or other plating material to provide a harder and/or more durable finish in an electroplating process. In other cases, the engraving is done directly on the nickel or other material plating layer. In some embodiments, the nickel, whether plated prior to or after engraving, may be a high phosphorous nickel with a content of between 8 and 15% because this content provides a smoother surface with better overall surface quality and therefore better structures may be formed in the cylinder/embossing roller and later with roller in extrusion or other film fabrication processes. The frequency and, therefore, the corresponding size of these structures formed in the cylinder's surface may be several thousand an inch or less than 100 per inch which allows later extrusion or forming of matching or corresponding TIR structures in a PV enhancement film.

Differing embossing rollers would be used to form three dimensional TIR structures such as pyramidal absorption enhancement structures desired for some PV enhancement films. These types of structures can be made or formed in a cylinder's surface in a variety of manners. In one exemplary process, diamond turning is used for engraving in one direction and then “crossing” the engraving going the other direction (such as diagonally across the cylinder surface in one direction such as plus 45 degrees and then diagonally across the cylinder surface in a second direction such as minus 45 degrees from an orthogonal travel or cutting path) leaving a diamond structure (mirror image) for the PV enhancement film manufacturing process. Sometimes this is referred to as a “knurling” process.

Another method of engraving these structures in the embossing cylinder surface may involve photonics and/or other photo-emulsion processes generally using lasers to expose photo-polymeric materials and then “washing out” the unwanted materials. In this process, the laser exposes areas of the cylinder or a flat plate using 5 or more axes, much like the diamond turning tool. The laser exposes the material with a pattern defining or mapping file stored in memory and accessed by a control software program run by one or more processors of the engraving system or machine. The correct exposures and angles may be defined in this data file, too, and may be used to expose the material as desired to achieve a particular result. After the unwanted material is washed out of the photopolymer, a plate or “shim” can be made from the process. This plate can be cast and reversed in nickel or other metals, can be metallized with an electrical metallization process, or can be cast and reversed with other polymers. The engraving or shim fabrication may also use methods used in holographic manufacturing processes.

Another method of engraving may involve the use of a CNC type engraving press. This engraving method may include engraving directly onto a shim, usually made of brass, copper, aluminum, or stainless steel. The shims may also be nickel plated in which the nickel itself is engraved directly. The shims in this method of engraving generally may be small, usually less that 8 inches by 8 inches. The engraving may be performed with a spinning diamond tool. The engraving CNC machine may also be multiple axis, tilting in all directions, and moving up and down in elevation. In this type of engraving, it may be easier to create three dimensional structures criss crossing in multiple directions with a spinning diamond tool. Extremely fine structures can be made with this technique, down to holographic and diffraction grading. For this invention, structures in frequencies of several thousand per inch can be made. It is also useful to note, that this method may be preferred for the accurate production of three and four sided pyramidal structures. In the future, these structures may also be tailor made to reflect certain wavelengths while directing other wavelengths in both TIR structures as well as elongation structures. These structures can be made fine enough to deflect (reflect) unwanted longer wavelengths that can decrease PV performance as well as re-direct the shorter wavelengths (generally 700 nanometers or less) that contain more energy but less heat. This technique will be advantageous to increasing PV performance in these film enhancement products in future generations or planned/envisioned embodiments.

The mirror image of the structure is engraved on a shim. The shim is then electroformed so that an exact mirror image of the shim is produced. This is then repeated to create a replica of the original engraving. This process is then repeated several dozen, several hundred or even several thousand times. These shims can then be placed upon a cylinder or platen covering the entire surface and glued, welded or framed in place to create a large embossing surface. This method is typically used in holography and is preferential, in some cases, to many other methods for engraving because a small part can be engraved and then reproduced inexpensively multiple times with electroforming. Care can be taken to make a small part carefully, and then reproduce that part inexpensively to cover a large cylinder or platen.

In some cases, the cylinder may be formed by applying or attaching a plurality of such plates or shims together to form the embossing surface for a roller. Typically, very fine structures can be made with this process and angles and structures can be chosen and produced accurately. In many cases, there will be a limitation in the size of the shim and multiple shims would need to be joined together to complete a cylinder. There will be visible “seams” in these shims. For many PV enhancement films, such seams or gaps will have little effect and will not meaningfully diminish the performance of the film or glass.