# Patent

## Title
Compact optics for concentration and illumination systems

## Abstract

An optical concentrator having a concentrating element for collecting input light, a redirecting element for receiving the light and also for redirecting the light, and a waveguide including a plurality of incremental portions enabling collection and concentration of the light onto a receiver. Other systems replace the receiver by a light source so the optics can provide illumination.

## Background
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
This application is a continuation-in-part and claims priority from U.S. patent application Ser. No. 12/705,434, filed Feb. 12, 2010, which is a continuation of U.S. Pat. No. 7,664,350, filed Sep. 9, 2008, which is a continuation-in-part of U.S. Pat. No. 7,672,549, filed Sep. 10, 2007, all of which are incorporated herein by reference in their entirety.
This invention is directed to an optical concentrator for producing electrical, thermal and radiative energy, and also to an optical illuminator employing the structure and methods described hereinafter. More particularly, the invention is directed to a solar concentrator using a combination of optical elements to concentrate and aggregate sunlight. Other applications include lighting and illumination using the compact optics.


BACKGROUND OF THE INVENTION
Solar collectors have long been developed for the collection and concentration of sunlight. Increasing the energy density of ambient sunlight enables more efficient conversion to useful forms of energy. Numerous geometries and systems have been developed, but the mediocre performance and high costs of such systems do not permit widespread use. In order to achieve adequate performance and manufacturability, improvements in solar energy collectors are needed.
SUMMARY OF THE INVENTION
A concentrator system includes a combination of optical elements comprising a concentrating element, such as a refractive and/or reflective component, a reflective and/or refractive element to redirect sunlight into a light waveguide which is constructed with a plurality of stepped reflective surfaces for efficient aggregation and concentration into a receiver unit (thermal and/or photovoltaic) and other conventional energy conversion systems. The control of the geometry of the reflective surfaces along with the aspect ratio of the light waveguide enables ready manipulation, collection and concentration of sunlight preferably onto a contiguous area for a variety of commercial applications, including solar cell devices, light pipe applications, heat exchangers, fuel production systems, spectrum splitters and other secondary manipulation of the light for various optical applications. These structures and methods can also be applied advantageously for a wide variety of optical illumination applications.
These and other objects, advantages and applications of the invention, together with the organization and manner of operation thereof, will become apparent from the following detailed description when taken in conjunction with the accompanying drawings.



BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a solar energy concentrator generally constructed in accordance with an embodiment of the invention;
FIG. 2 illustrates a cross-sectional view of one embodiment of a light waveguide shown schematically in FIG. 1;
FIG. 3 illustrates another cross-sectional view of a linear embodiment of a light waveguide shown schematically in FIG. 1;
FIG. 4 illustrates another cross-sectional view of a rotational embodiment of a light waveguide shown schematically in FIG. 1;
FIG. 5A shows a first edge shape of a reflecting element of a waveguide; FIG. 5B shows a second edge shape for a reflecting element of a waveguide; FIG. 5C shows a first separate element for redirecting light as part of a stepped waveguide; FIG. 5D shows a second separate element for redirecting light as part of a stepped waveguide; FIG. 5E shows a system with plural light pipes coupled to a stepped waveguide and FIG. 5F shows a waveguide with embedded redirecting components;
FIG. 6 shows a curved concentrating element and curved reflector coupled to a waveguide;
FIG. 7 shows a curved concentrating element and two planar reflectors coupled to a waveguide;
FIG. 8A shows a closed optical element coupled to a waveguide and FIG. 8B shows an enlarged view of a portion of FIG. 8A at the juncture of the optical element and waveguide;
FIG. 9A shows another closed optical element coupled to a waveguide and FIG. 9B shows an enlarged view of a portion of FIG. 9A at the juncture of the optical element and the waveguide;
FIG. 10A shows another closed optical element coupled to a waveguide and FIG. 10B shows an enlarged view of a portion of FIG. 10A at a juncture of the optical element and the waveguide;
FIG. 11A shows a further closed element coupled to a waveguide and FIG. 11B shows an enlarged view of portion of FIG. 11A at a juncture of the optical element and the waveguide; and
FIG. 12 shows ray tracing results for the optical systems of FIGS. 2 and 6-11.
FIG. 13 illustrates another representation of an embodiment of a solar energy concentrator or an illuminator;
FIG. 14 illustrates a refractive concentrator component for a conventional system;
FIG. 15 illustrates a reflective concentrator component for another conventional system;
FIG. 16 illustrates a Cassegrainian concentrator having a primary and secondary reflective optic;
FIG. 17 illustrates light transmission versus acceptance angle for a system like FIG. 13.
FIG. 18 illustrates an embodiment where the waveguide ends with a reflector component for redirecting light towards a base surface;
FIG. 19 illustrates a variation on FIG. 18 where the concentrator is mirrored about an axis of symmetry;
FIG. 20 illustrates a form of the embodiment of FIG. 13 with the waveguide and redirecting elements tilted relative to the concentrators;
FIG. 21 illustrates an embodiment with varying size of concentrator and/or redirecting element;
FIG. 22 illustrates an embodiment for light diffusion using a light source in place of a receiver;
FIG. 23 illustrates a different variation on the embodiment of FIG. 4 to achieve light concentration across two axes;
FIG. 24 illustrates yet another embodiment to achieve concentration across two axes;
FIG. 25 illustrates a different embodiment of a solar concentrator of the invention;
FIG. 26 illustrates yet another embodiment of a solar concentrator of the invention;
FIG. 27 illustrates a further embodiment of a solar concentrator of the invention
FIG. 28 illustrates a different embodiment of an optical concentrator of the invention;
FIG. 29 illustrates a different embodiment of an optical concentrator of the invention;
FIG. 30 illustrates a different embodiment of an optical concentrator of the invention;
FIG. 31 illustrates a different embodiment of an optical concentrator of the invention;
FIG. 32 illustrates a different embodiment of an optical concentrator of the invention;
FIG. 33 illustrates a different embodiment of an optical concentrator of the invention;
FIG. 34 illustrates a different embodiment of an optical concentrator of the invention;
FIG. 35 illustrates a different embodiment of an optical concentrator of the invention;
FIG. 36 illustrates a different embodiment of an optical concentrator of the invention;
FIG. 37 illustrates a different embodiment of an optical concentrator of the invention;
FIG. 38 shows a waveguide with entry elements;
FIG. 39 illustrates a different embodiment of a waveguide with entry elements;
FIG. 40 illustrates a different embodiment of a solar concentrator of the invention;
FIG. 41 illustrates a different embodiment of an optical concentrator of the invention;
FIG. 42 illustrates a different embodiment of an optical concentrator of the invention;
FIG. 43 illustrates a different embodiment of an optical concentrator of the invention;
FIG. 44 illustrates a different embodiment of an optical concentrator of the invention;
FIG. 45 illustrates a different embodiment of an optical concentrator of the invention;
FIG. 46 illustrates a different embodiment of a solar concentrator of the invention with symmetry about a central axis;
FIG. 47 shows an extruded view of FIG. 46 with positioning elements;
FIG. 48 illustrates examples of transverse optical elements and positioning elements;
FIG. 49 shows an extruded view of FIG. 46 with transverse optical elements.



DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A solar energy concentrator system constructed in accordance with a preferred embodiment of the invention is indicated schematically at 10 in FIG. 1. The solar energy concentrator system 10, includes an optical concentrating element 12 which can be any conventional optical concentrator, such as an objective lens, a Fresnel lens, and/or a reflective surface element, such as a parabolic or compound shaped reflector. This optical concentrating element 12 acts on input light 14 to concentrate the light 14 to a small focal area 16. In the preferred embodiment, the small focal area 16 is disposed within reflective or redirecting component 18, or other conventional optical redirecting element which causes total internal reflection. The redirecting component 18 redirects the concentrated light 20 into a waveguide 22. The waveguide 22 is constructed to cause internal reflection of the light 20 which propagates along the waveguide 22 in accordance with Snell's law wherein total internal reflection occurs when the angle of the light 20 incident on surface 24 of the waveguide 22 is greater than the critical angle, Øc:

Øc=sin(ηwaveguide/ηcladding)

    
    
        Where Øc=critical angle for total internal reflection,
        ηwaveguide=refractive index of waveguide material
        ηcladding=refractive index of a cladding layer or the index at the ambient/waveguide interface.
    
    


A receiver 26 is disposed at the end of the waveguide 22 and receives the light 20 for processing into useful energy or other optical applications.
FIG. 13 illustrates a preferred form of the system 10 with details of this mechanism. A plurality N of concentrating elements 12 and redirecting elements 18 are shown. Each of the concentrating elements 12 takes the input light 14 with a half angle of θ1 from an area A, and concentrates the light 14 to a smaller area B with half angle θ2, such that Concentration Ratio=A/B. Each of the redirecting elements 18 receives the concentrated light from an associated one of the concentrating elements 12, rotates it by some angle φ, and inserts it into a section of the waveguide 22, preserving the level of concentration defined by area B and half angle θ2. The waveguide 22 is a plurality of sections having incremental steps of height B that are spaced from each other by length A. Each section of the waveguide 22 receives light from an associated one of the redirecting elements 18, such that the waveguide 22 as a whole aggregates light from the plurality of the concentrating elements 14 and the redirecting elements 18, and propagates the light 14 along its length for collection by a receiver 23. The waveguide 22 does not change the level of concentration delivered to it, and therefore the aspect ratio of the waveguide 22




  
    
      
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Compactness has great practical benefits for solar concentrators (and other devices such as illuminators). Among other benefits: less material is used, large air gaps between optics and the receiver 23 that need difficult sealing are eliminated, devices are much less bulky for cheaper shipping and installation, traditional flat module manufacturing methods can be utilized as opposed to expensive and risky custom manufacturing methods.
The limit of compactness for the waveguide 22 is defined by the receiver 23. Thus, the waveguide 22 can only be as compact as the receiver 23 to which it delivers light. For most concentrators, the compactness of the concentrator 12 is significantly larger than the width of the receiver 23. However, since this device constructs the waveguide 22 from sections each having height defined by the area of concentrated light delivered to it, the aggregated waveguide 22 has a height equal to the width of the receiver 23. In other words, the waveguide 22 is at the limit of compactness.
Therefore in view of the construction of the invention, the concentration of light achieved by the concentrator system 10 being a function of the aspect ratio A/B leads to a highly compact concentrator system 10. The device can aggregate light from a relatively wide area and concentrate it to a relatively small receiver that has a contiguous area while remaining highly compact. This simplifies production by reducing the volume of material required, allowing for multiple units to be made from a single mold and reducing assembly complexity.
FIG. 12 shows the results of ray tracings performed on the designs depicted in FIGS. 2 and 6-11. Each design demonstrates a particular performance in terms of its ability to concentrate light in the linear dimension, as shown by the ratio of A/B. The data is for light having an input cone half angle of +−1 degree, an output cone half angle of +−20 degrees, an initial refractive index of n=1, and a final refractive index of n=1.5. The theoretical maximum allowable concentration of light with those input parameters is 30× in the linear dimension, whereas FIG. 9 for example achieves a concentration factor of 25×. Since the concentration factor in the linear dimension is proportional to the aspect ratio A/B, the design shown in FIG. 9 can deliver a concentrator that is 250 millimeters long (A) while only 10 millimeters in thickness (B); or a concentrator that is 500 millimeters long (A) while only 20 millimeters in thickness (B). This represents a highly compact concentrator system 10 that can effectively aggregate concentrated light from a relatively wide area and deliver it to a single receiver.
The dimensions and number of the concentrating elements 12 and redirecting elements 18 can be varied for any entry aperture of the concentrator 12. For example, the system 10 shown in FIG. 13 can be achieved with twice as many elements (2×N) of half the size (A/2 and B/2). As the concentrating elements 12 and the redirecting elements 18 become smaller and more numerous, the aspect ratio of the entire concentrator 12 approaches the aspect ratio of the waveguide 22, given by 1/Concentration Ratio. In other words, for a Concentration Ratio of 10, the aspect ratio of the concentrator 12 can be 0.1.
Typical aspect ratios for concentrators 12 are on the order of 1. FIG. 14 shows a refractive concentrator 12, which may be, for example, an objective lens or a Fresnel lens. The focal length of an objective lens defines the height 25. The Concentration Ratio is given by A/B, whereas the aspect ratio is given by height/A, which is larger than the Concentration Ratio. FIG. 15 shows a similar situation for a reflective form of the concentrator 12.
Attempts have been made to reach the limit of compactness for a single concentrating element. FIG. 16 shows a Cassegrainian concentrator composed of a primary and secondary reflective optic. The aspect ratio given by Height/A is 0.25. Winston, in “Planar Concentrators Near the Etendue Limit”, 2005, describes the “fundamental compactness limit of a 1/4 aspect ratio.” In the context of the invention, this compactness limit applies to an individual one of the concentrating elements 12. The use of the waveguide 22 that aggregates light from multiple ones of the concentrating elements 12 is what allows the compactness of the system 10 to go lower than 1⁄4 and approach 1/Concentration Ratio.
The invention also has advantages in the transmission efficiency of light energy from input to delivery to the receiver 23. In FIG. 13, θ2 is controlled by the concentrating element 12. θ2 also becomes the angle made by the light hitting the surface of the waveguide 22, and 90−θ2 is the angle made with respect to the normal of the waveguide surface. As discussed above, θ2 can be set to achieve total internal reflection within the waveguide 22, reducing surface absorption losses to zero.
In addition, the concentrating element 12 and redirecting element 18 can be designed to manipulate the light 14 using total internal reflection, as shown in specific embodiments below. Also, the concentrating element 12 and redirecting element 18 and the waveguide 22 can be designed to provide a contiguous path within a solid dielectric medium for the light 14. In other words, light rays from the input region to the receiver 23 need never encounter either a reflective coating or a change in refractive index. Reflective coatings can cause absorption losses of  ̃8%. A change in refractive index from an optical material of refractive index 1.5 (plastic or glass) to air can cause Fresnel reflection losses of  ̃4%. Transmission efficiency with respect to these loss mechanisms can therefore approach 100%.
This is in contrast to conventional concentrator optics. Reflective optics will have 8% loss per reflection. Transmission efficiency will therefore be  ̃92% for a single optic, and  ̃85% when a secondary reflective optic is used. Refractive optics require at least one change in refractive index. Transmission efficiency will therefore be  ̃96% for a single optic, and  ̃92% when a secondary refractive optic is used.
FIG. 17 shows transmission as a function of input half angle θ1 through the embodiment of the invention shown in FIG. 13. The calculation is based on ray tracing software. The embodiment was designed to function within input angles of +−3 degrees. The efficiency takes into account losses from Fresnel reflections and hard reflections. As is shown, the efficiency of the device approaches 100% at θ1=0 degrees, stays near 100% within +−3 degrees, and then drops off sharply.
In another preferred form of the concentrator system 10 shown in FIG. 2, the incident light 14 is concentrated or focused in a first step using the element 12 described hereinbefore. The concentrated light 20 is further processed by associating sections of the concentrator system 10 with reflector/waveguide sections 28. Each of the reflector/waveguide sections 28 comprises a reflective section 32 which receives the concentrated light 20 and redirects light 30 within the associated waveguide section 28 with the light 30 undergoing total internal reflection (TIR) along the length of the entire waveguide 22. A plurality of the reflector/waveguide sections 28 comprise the waveguide 22 and forms a stepped form of waveguide construction.
FIG. 18 shows another embodiment of the system 10 where the waveguide 22 ends in a reflector 27 that redirects the light 14 towards the base surface of the waveguide 22, where the receiver 23 may be placed. It can be of manufacturing benefit to have the concentrator optics be laid down flat onto a plane of conventional receiver elements which embody the receiver 23.
With this construction, the concentrator 12 can be mirrored about an axis of symmetry as shown in FIG. 19, such that the two receivers 23 from either end form one contiguous area where one single receiver 23 may be placed. In this case, since the aperture area is doubled but the thickness of the concentrator 12 unchanged, the limit of compactness is given by 1/(2× Concentration Ratio).
The redirecting element 18 rotates the light paths by an angle φ. In FIG. 13, φ is shown to be 90 degrees. FIG. 20 depicts φ<90 degrees. This can allow, as one benefit, the concentrating elements 12 to be located on the same plane, and the redirecting elements 18 on their own plane as well, which can aid manufacturability.
The concentrating element 12 and the redirecting element 18, and associated waveguides 22, may also vary in size and FIG. 21 shows an example of this. Here A1, A2, and A3 are different lengths, as are B1, B2 and B3. However, the Concentration Ratio stays the same in each section: A1/B1=A2/B2, and so on. The aspect ratio of the waveguide 22 is therefore still given by




  
    
      
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In another embodiment shown in FIG. 22, the system 10 can also be utilized as a light diffuser by running light 31 through it in reverse. In FIG. 22, light input from a light source 33 that was originally the receiver 23, is channeled through the waveguide 22, redirected by the redirecting element 18 onto the concentrating element 12, which delivers the output light above the system 10. Applications include illumination, backlighting, and other light diffusing devices. It should be understood throughout that optics illustrated for concentration of light can also be used for illumination with the “receiver 23” being replaced by a light source.
The cross-section of the various reflector/waveguide sections 28 provides a basic building block for various configurations of the concentrator system 10. One exemplary commercial embodiment is shown in FIG. 3 with an aspect ratio N×B/N×A, A/B, an area concentration factor or energy density ΔØ which is proportional to A/B where N×A is the length of the waveguide 22 and N×B is the largest thickness (see FIGS. 2 and 3). In a most preferred embodiment, the thickness N×B is comprised of a plurality of incremental step heights, B, which provide a clear light pathway for TIR light from each of the reflector/waveguide sections 32.
FIG. 4 illustrates another example of the concentrator system 10 in the form of a rotationally (or axially) symmetric geometry having a concentrator system 10′ and the concentrating element 12 in association with the reflector/waveguide sections 28 of the waveguide 22. This rotationally symmetric form of the concentrator system 10′ (or the system 10), which can be any portion of a full circle, enables three dimensional radial convergence of the incident light 14 resulting in ΔØ the Concentration Ratio being proportional to (A/B)2 thereby substantially enhancing collection and concentrator efficiency. In a most preferable embodiment of FIG. 4 two axis solar tracking is used as opposed to the single axis tracking for the embodiment of FIG. 3.
FIG. 4 shows one way to achieve concentration across two axes, and FIG. 23 shows another way. Here, a linearly symmetric primary concentrator 12 delivers light concentrated along one axis to its receiver 23 at the side of a concentrator 12. There, a second linearly symmetric concentrator 37 is positioned in the perpendicular axis. This secondary concentrator 37 concentrates light along the second axis, bringing the light to the final receiver 23.
FIG. 24 shows a third way to achieve concentration across two axes. Here the concentrators 12 shown are of the mirror symmetry as described in FIG. 19. Again, a linearly symmetric primary concentrator 12 delivers light 14 concentrated along one axis to its receiver 23 at the base of the concentrator 12. There, a second linearly symmetric concentrator 37 is positioned in the perpendicular axis. This secondary concentrator 37 concentrates the light 14 along the second axis, bringing the light to the final receiver 23.
In addition to the linear and rotational embodiments of FIGS. 3 and 4, the concentrator system 10′ can be disposed both above and/or below the waveguide 22 relative to the direction of the incident light 14. In such embodiments, some of the light 14 will pass through the waveguide 22 and be redirected back to the waveguide 22 by the concentrator system 10′. These forms of systems enable light recycling and thus improve end efficiency and the use of the reflective systems for concentration, described herein, show an increased efficiency for concentration of light relative to conventional refractive system.
In other embodiments, the reflective elements 18 can be angularly adjusted with respect to the waveguide 22 in order to cause TIR. The reflective element 18 can be an integral part of the waveguide 22 with a variety of angular profiles (see FIGS. 5A and 5B). The element 18 also can be separate elements 38 and 39 (see FIGS. 5C and 5D). In addition, the reflective element 18 and the associated waveguide 22 can also take the form of complex light collector pipes 42 and light redirecting components 43 as shown in FIGS. 5E and 5F, respectively.
The above described forms of the concentrator system 10 and 10′ provide concentrated light 20 to a contiguous area as opposed to a nodal area, thereby allowing delivery of concentrated solar energy to a variety of downstream receivers 26, such as a solar cell, a light pipe for further processing, a heat exchanger, a secondary concentrator and a light spectrum splitter.
In yet another series of embodiments shown in FIGS. 6-11B, a variety of optical components can be used in combination to further and substantially enhance both the concentration and collection efficiency. FIG. 6 in a most preferred embodiment shows a curved concentrating element 50 directing light 52 onto a curved reflector 54 which passes the light 52 into the waveguide 22. FIG. 7 in another most preferred embodiment shows another curved concentrating element 56 which directs the light 52 off a reflector 58 having two planar surfaces 59 and 60 which redirect the light 52 by TIR into the waveguide 22. FIG. 8A shows a partially closed optical element 64 which redirects the light 52 at interface 66, reflects the light 52 off curved reflector 68 focusing the light 52 onto interface 70 between a bottom reflective surface 72 of the optical element 64. As best seen in the enlarged view of FIG. 8B, the waveguide 22 has a substantially complementary angular match to the reflective surface 72.
In FIG. 9A in another most preferred embodiment is a similar system as in FIG. 8A, but the optical element 65 is closed and coupled to an extension waveguide 74 (a form of light pipe) which collects the light 52 and transmits it into the waveguide 22 (as best seen in FIG. 9B).
In FIG. 10A an optical element 76 is closed with the input light 52 reflected by TIR from reflective surface 77 with a particular angular cross section best shown in FIG. 10B which enables collection of the light from TIR and coupling with the waveguide 22 from reflection off surfaces 80, 81 and 82.
In FIG. 11A an optical element 82 cooperates with another reflector 84 to direct the light 52 into the waveguide 22 from the two different optical sources 82 and 84, thereby further ensuring collection of all the light incident on surface 86 of the optical element 82. In this embodiment the optical elements 82 and 84 perform the role of both concentrating elements and reflecting elements.
In FIG. 25, a curved concentrating element 12 directs the light 14 onto (the redirecting component 18) which passes the light 14 into the waveguide 22. The concentrating element 12 and the redirecting component 18 are shown as two different features on the same physical part, while the waveguide 22 is shown as a second physical part coupled to the first. In FIG. 26, a curved concentrating element 12 directs the light 14 onto two reflectors (the redirecting component 18) acting in sequence which pass the light 14 into the waveguide 22. The concentrating element 12, the redirecting component 18, and waveguide 22 are all shown as separate physical parts coupled together. FIG. 27 directs the light 14 into the waveguide 22 similar to FIG. 26. However, the redirecting component 18 and the waveguide 22 are combined into one construction.
In FIG. 28, a refractive concentrating element 12 directs the light 14 onto a redirecting element 18 which reflects the light 14 into the waveguide 22. The redirecting elements 18 are preferably integrated into the waveguide structure as incremental step features. In FIG. 29, the concentrating elements 12 and redirecting elements 18 are similar to those in FIG. 28, but the top surface of the waveguide 22 is angled so that the waveguide 22 has a substantially uniform cross-sectional thickness along its length.
FIG. 30 is similar to FIG. 29, except that the redirecting elements 18 and the waveguide 22 are rotated such that the waveguide is substantially parallel to the plane of the concentrating elements 12. FIG. 31 is similar to FIG. 30, except with an additional set of redirecting elements 87 that refract the light from the concentrating elements such that the incident angle of light onto redirecting element 18 is larger than the comparable incident angle of light in FIG. 30. This, for example, better facilitates total internal reflection as the mechanism of redirection for the redirecting element 18. FIG. 32 is similar to FIG. 31, except the top surface of the waveguide 22 is a tailored shape 88. The tailored shape 88 is useful for example in delivering the light propagating through the waveguide to a defined spot or location L at the end of the waveguide 22.
In FIG. 33, the redirecting elements 18 are integrated into a single part that is separate from the parts carrying the concentrating elements 12 and the waveguide 22. The redirecting element 18 may be of any type previously described in this application, and is shown as a curved reflective element similar to that in FIG. 6. The waveguide 22 is comprised of incremental step features 89 which are positioned to receive the light from the redirecting elements 18. FIG. 34 is similar to FIG. 33, except that the base surface 90 of the waveguide 22 is angled so that the waveguide has a substantially uniform cross-sectional thickness along its length. FIGS. 35 and 36 show the base surface of the waveguide 22 are of tailored shapes 88, shown as flat facets 88 and a curved element 88 respectively. As in FIG. 32, the tailored shape 88 is useful for example in delivering the light propagating through the waveguide 22 to a defined spot L at the end of the waveguide 22.
FIG. 37 is similar to FIG. 30 except that the concentrating element 12 is a Fresnel lens. The Fresnel lens may be manufactured for example by injection molding, hot embossing or microreplication of polymeric materials or other materials suitable to those processes.
FIG. 38 shows a waveguide 22 with entry elements 91 on the top surface, similar to those in FIG. 33-36. FIG. 39 shows a similar waveguide 22, except that the entry elements 91 are integrated as a separate part, which is then optically attached to the flat top surface of the bulk waveguide element 22 via an optical coupling layer 92. The light entry elements are therefore physically discontinuously disposed from the body of the waveguide. This allows the use of for example manufacturing processes based on thin film substrates to make the entry element features. FIG. 40 shows the waveguide 22 shown in FIG. 39 operating within an example of a full optical design. A concentrating element 12 concentrates light 14 onto a redirecting element 18, which redirects the light 14 for insertion into the waveguide 22 via the entry elements 91.
FIG. 41 is similar to FIG. 30, except that the part containing the concentrating elements 12 is optically coupled to the waveguide 22 using a low index adhesive 93. This construction eliminates an air gap between the concentrating elements 12 and the waveguide 22, and therefore diminishes optical losses due to the Fresnel reflection effect as light travels from the concentrating elements 12 to the waveguide 22. The low index adhesive 93 needs to be of an appropriate refractive index, lower than the refractive index of the waveguide 22, in order to enable propagation of light within the waveguide 22 using total internal reflection. The low index adhesive 93 may for example be a silicone elastomer such as Dow Corning Sylgard 184. FIG. 42 is similar to FIG. 41, except that the concentrating element 12 is a Fresnel lens rather than an asymmetric bulk lens.
In FIG. 43, the concentrating element 12 directs the light 14 to a first redirecting element 87 that refracts the light 14, directing the light 14 onto the second redirecting element 18, which redirects the light into the waveguide 22 for propagation. In FIG. 43, the first redirecting element 87 is a flat facet. FIG. 44 is similar to FIG. 43, except that the first redirecting element 87 interacts with light 14 prior to the concentrating element 12. In FIG. 45, the waveguide 22 propagates light 14 bi-directionally or in multiple directions across its length. The concentrating element 12 concentrates light onto redirecting elements 18 and 94, with the two redirecting elements 18 and 94 redirecting the light in opposing directions into the waveguide 22. This construction allows light to be concentrated and collected at both ends of the waveguide 22.
In FIG. 46, the concentrating element 12 concentrates the light 14 onto the redirecting element 18. The redirecting element 18 has two parts, a flat facet 95 which refracts the light into the bulk optic, and another flat facet 96 which reflects the light into the waveguide 22. The redirecting facets 95 and 96 and the waveguide 22 are integrated into a single part. The end of the waveguide has a facet 99 that redirects the light downwards towards the receiver 23, as previously described in para [0059]. In this embodiment, the waveguide 22 has the waveguide 97 as its mirror image about axis 98. The placement of secondary optics at the end of the waveguide 22 and the symmetric layout of waveguides 22 can be implemented with all embodiments shown in this application, and has been previously explained in para [0049].
The redirecting elements 18 described in FIG. 1-46 are associated with corresponding concentrating elements 12, and transfer light into the waveguide 22 utilizing at least one of the optical mechanisms of reflection, total internal reflection, and refraction. The redirecting elements can be but need not be optically coupled with and physically separate from the concentrating elements.
In the various embodiments described above in this application, the concentrating element 12 is separated from at least a portion of the associated redirecting element 18 by a layer. The light 14 does not undergo any repositioning change of direction within this layer. The layer itself is contiguous between at least a portion of each of the associated redirecting elements 18. This separating layer enables the concentrating elements 12 and redirecting elements 18 to be disposed in a vertical stack of physically separate components. This enables direct assembly of separate parts to form the overall solar concentrator.
In order to minimize cost and simplify design, one practical challenge is to achieve all the functionality described above in as few parts as possible with robust materials. Generally, this involves incorporating multiple functions into only a few parts. For instance, by patterning optical features into a coverglass it is feasible to enable the glass to both protect the module and act as the concentrating element 12 while preserving its ability to act as a substrate for various optical coatings. By applying a cylindrical metal roll with machined concentric features to softened glass, large glass manufacturing facilities can routinely form mild lens features on one side of a sheet Given the proper roll design to impress optical features, linear lenses may be patterned on the coverglass to form the primary optic (concentrating) element 12. The concentrating element 12 can be oriented in both outward and inward facing directions while preserving functionality. Outward facing features run the risk of particulate accumulation, also known as soiling, which is detrimental to light transmission. In addition to manipulated coverglass approaches, features can be added to a flat coverglass using processes such as silicone deposition which also provide concentrating functionality.
Further, it is possible to construct a complementary secondary optical part that serves as the redirecting element 18 for the concentrated light 14 from the coverglass layer and act as the waveguide 22 to deliver the redirected light 14 to the receiver 23 (FIG. 46). Note that in this embodiment the primary optic serves as both the protective coverglass and concentrating layer while the redirecting and waveguide functions can be combined in the secondary optic. Similarly, for point-focus designs, an axially symmetric lens pattern may be applied to glass using a hot embossing or mold-type process.
Incorporating optical functionality into the coverglass and combining the redirecting and waveguide-to-focal-area functionality into one part enables the entire optical path to be managed or achieved by only two parts. One critical aspect of this two-part class of ATIR optics is that both the vertical and horizontal position of the waveguide or secondary optic must be well maintained relative to the primary optic layer (coverglass). In other terms, maintaining the geometry of the separating layer is critical to ensuring robust functionality. One way to achieve this is by incorporating yet another function within either the primary or secondary/waveguide optical parts. For instance, as shown in FIG. 47, by incorporating a positioning element, or rib feature, 100 into the secondary optic, it is possible to mechanically interlock the primary and secondary optic parts, constraining them in both the vertical and horizontal dimensions to ensure a stable separation. The positioning element 100 therefore maintains geometrical relationships between the plurality of optical elements and the waveguide in the horizontal, vertical, and rotational planes.
Another option for production is to create a separate supporting positioning element or rib feature 100. This option carries the disadvantage of having to make another separate part. However, the rib feature is so simple that the tooling cost for molding this part can be low, and the assembly becomes more modular—allowing design flexibility in the way that ribs and secondary optic parts are assembled. FIG. 48 shows renderings illustrating complimentary optical secondary and support rib feature 100. These parts can be assembled in a modular fashion to provide design flexibility. The positioning element 100 can therefore be either an integral part of the waveguide or a separate element from the waveguide.
It is likely that a viable receiver may consist of multiple discrete photovoltaic solar cells. When stringing solar cells together it is advisable to leave a gap between cells to manage stress concentrations around solder joints and minimize cell breakage. The effect of these gaps is to reduce the area from which light energy may be gathered. These gaps are useful locations for positioning non-optically-active support features such as the positioning elements or ribs 100. Also, the optic may be adapted with an optical redirecting element, or notch feature, 101 so as to direct the majority of light that would have otherwise fallen onto the gap towards active receiver (FIG. 49). The notch feature 101 is similar to a redirecting element but oriented in a different plane of the waveguide 22 so as to internally reflect light away from gaps and onto an active receiver. The notch or transverse optical element 101 is coupled to the waveguide 22 and redirects the light in the transverse direction to the direction of propagation of light within the waveguide 22. Previously, secondary optical elements 27 have been described which couple to the waveguide and redirect light from the waveguide to the light receiver. When the above-mentioned transverse optical elements 101 are utilized, the secondary optical elements 27 redirect light from the waveguide and from the transverse optical elements to the light receiver.
The foregoing description of embodiments of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the present invention to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the present invention. The embodiments were chosen and described in order to explain the principles of the present invention and its practical application to enable one skilled in the art to utilize the present invention in various embodiments, and with various modifications, as are suited to the particular use contemplated.

## Claims

1. An optical concentrator, comprising:
a plurality of optical elements disposed adjacent each other with each of the plurality of optical elements including:
a) a concentrating element for collecting and repositioning light; and
b) an associated redirecting element which is associated with and separate from the concentrating element for receiving light from the concentrating element wherein the concentrating element of each of the plurality of optical elements is separated from at least one portion of the associated redirecting element by a layer within which the light does not undergo a repositioning change of direction and the layer being contiguous between at least a portion of each of the associated redirecting elements; and the optical concentrator further including:
a stepped waveguide for receiving the light from the at least one portion of the associated redirecting element which is constructed to reposition the light into the stepped waveguide for accumulation;
secondary optical elements coupled to the stepped waveguide that redirect the light from the waveguide towards a light receiver; and
a light receiver for receiving the light from the stepped waveguide.

2. The optical concentrator as defined in claim 1 where the stepped waveguide includes upper and lower surfaces that are substantially parallel.

3. The optical concentrator as defined in claim 1 where the stepped waveguide includes a substantially uniform thickness along its length.

4. The optical concentrator as defined in claim 1 where the stepped waveguide includes a surface selected from the group of a flat facet, a curved surface, and a tailored shape.

5. The optical concentrator as defined in claim 1 where the stepped waveguide includes light entry elements that are associated with the associated redirecting elements, the light entry elements being physically discontinuously disposed from the body of the stepped waveguide, thereby enabling assembly of the stepped waveguide in separate parts.

6. The optical concentrator as defined in claim 1 where the concentrating elements are optically coupled to the top surface of the waveguide.

7. The optical concentrator as defined in claim 1 where the redirecting elements are optically coupled to the top surface of the waveguide.

8. The optical concentrator as defined in claim 1 where the optical elements are positioned structurally to insert the light into the stepped waveguide such that light is propagated bi-directionally within the stepped waveguide.

9. The optical concentrator as defined in claim 1 where the concentrating elements are made by patterning optical elements in a glass sheet.

10. The optical concentrator as defined in claim 1 where the associated redirecting element is optically coupled with and physically separate from the concentrating element.

11. A optical concentrator, comprising:
a plurality of optical elements disposed adjacent each other with each of the plurality of optical elements including:
a) a concentrating element for collecting and repositioning light; and
b) a redirecting element comprised of 1) a first redirecting element portion receiving the repositioned light from the concentrating element and refracting the light onto a second redirecting element, and 2) a second redirecting element receiving the light from the first redirecting element and repositioning the light via reflection; wherein the concentrating element of each of the plurality of optical elements is separated from at least one portion of the associated redirecting element by a layer within which the light does not undergo a repositioning change of direction and the layer being contiguous between at least a portion of each of the associated redirecting elements; and the optical concentrator further including:
a stepped waveguide for receiving the light from the at least one portion of the associated redirecting element which is constructed to reposition the light into the stepped waveguide for accumulation.

12. An optical concentrator, comprising:
a plurality of optical elements disposed adjacent each other with each of the plurality of optical elements including:
a) a refracting concentrating element for collecting and repositioning light; and
b) an associated redirecting element which is associated with and separate from the concentrating element for receiving light, from the concentrating element wherein the concentrating element of each of the plurality of optical elements is separated from at least one portion of the associated redirecting element by a layer within which the light does not undergo a repositioning change of direction and the layer being contiguous between at least a portion of each of the optical elements; and the optical concentrator further including:
a waveguide for receiving the light from the at least one portion of the associated redirecting element which is constructed to reposition the light into the waveguide for accumulation, the redirecting element being an integral part of the waveguide, the waveguide having top and bottom surfaces that are substantially parallel, the waveguide having a substantially uniform thickness along its length, and the optical elements are positioned structurally to insert the light into the waveguide such that light is propagated multi-directionally within the waveguide.

13. An optical concentrator, comprising:
a plurality of optical elements disposed adjacent each other with each of the plurality of optical elements including:
a) a concentrating element for collecting and repositioning light; and
b) an associated redirecting element which is associated with and separate from the concentrating element for receiving light from the concentrating element, wherein the concentrating element of each of the plurality of optical elements is separated from at least one portion of the associated redirecting element by a layer within which the light does not undergo a repositioning change of direction, and the layer being contiguous between at least a portion of each of the associated redirecting elements
the optical concentrator further including a stepped waveguide for receiving the light from the at least one portion of the associated redirecting element which is constructed to reposition the light into the stepped waveguide for accumulation; the above elements being constructed in a cross-section, the cross-section then being extruded to form the optical concentrator.

14. An optical concentrator, comprising:
a plurality of optical elements disposed adjacent each other with each of the plurality of optical elements including:
a) a concentrating element for collecting and repositioning light, wherein the light is repositioned along one axis of the concentrating element; and
b) an associated redirecting element which is associated with and separate from the concentrating element for receiving light from the concentrating element, wherein the concentrating element of each of the plurality of optical elements is separated from at least one portion of the associated redirecting element by a layer within which the light does not undergo a repositioning change of direction, and the layer being contiguous between at least a portion of each of the associated redirecting elements
the optical concentrator further including a stepped waveguide for receiving the light from the at least one portion of the associated redirecting element which is constructed to reposition the light into the stepped waveguide for accumulation.

15. A optical concentrator, comprising:
a plurality of optical elements disposed adjacent each other with each of the plurality of optical elements including:
a) a concentrating element for collecting and repositioning light; and
b) an associated redirecting element which is associated with and separate from the concentrating element for receiving light from the concentrating element wherein the concentrating element of each of the plurality of optical elements is separated from at least one portion of the associated redirecting element by a layer within which the light does not undergo a repositioning change of direction and the layer being contiguous between at least a portion of each of the associated redirecting elements; and the optical concentrator further including:
a waveguide for receiving the light from the at least one portion of the associated redirecting element which is constructed to reposition the light into the waveguide for accumulation; and
a positioning element which maintains geometrical relationships between the plurality of optical elements and the waveguide in the horizontal, vertical, and rotational planes.

16. The optical concentrator defined in claim 15 where the positioning element is an integral part of the waveguide.

17. The optical concentrator defined in claim 15 where the positioning element is a separate element from the waveguide.

18. A optical concentrator, comprising:
a plurality of optical elements disposed adjacent each other with each of the plurality of optical elements including:
a) a concentrating element for collecting and repositioning light; and
b) an associated redirecting element which is associated with and separate from the concentrating element for receiving light from the concentrating element wherein the concentrating element of each of the plurality of optical elements is separated from at least one portion of the associated redirecting element by a layer within which the light does not undergo a repositioning change of direction and the layer being contiguous between at least a portion of each of the associated redirecting elements; and the optical concentrator further including:
a stepped waveguide for receiving the light from the at least one portion of the associated redirecting element which is constructed to reposition the light into the stepped waveguide for accumulation, the stepped waveguide aggregating the light from the plurality of optical elements and propagating the light towards the light receiver;
transverse optical elements coupled to the stepped waveguide that redirect the light in the transverse direction to the direction of propagation of light within the waveguide;
secondary optical elements coupled to the stepped waveguide that redirect the light from the waveguide and the transverse optical elements towards a light receiver; and
a light receiver for receiving the light from the stepped waveguide.