Patent ID: 12242078

REFERENCE NUMERALS IN THE DRAWINGS

100Focal Lens102Low Band Thin Film SolarCell104Mid Band Thin Film106High Band Thin Film SolarSolar CellCell108aLow Band Dichroic110aHigh Band Dichroic Filter108bFilter Film110bFilm10a, 10bTransparent12aTransparent Adhesive10c, 10dTriangular Prism12bSection200Incident Solar202Focal LensRadiation204Solar Visible206Visible (High Band)SpectrumSpectrum Solar CellComponent208Visible Spectrum210Solar Vis-NIR SpectrumReflecting SurfaceComponent212Vis-NIR (Mid Band)214IR Spectrum ReflectingSpectrum SolarSurfaceCell216NIR (Low Band)218Solar IR SpectrumSpectrum SolarComponentCell300Focal Lens302Visible (High Band)Spectrum Solar Cell Group304Vis-NIR (Mid Band)306NIR (Low Band) SpectrumSpectrum SolarSolar Cell GroupCell Group308Cross Dichroic310Elongated Uniform CrossPrism AssemblySection Length400Solar Panel Frame402Solar Panel Sub Elements404Power ConversionElectronics

DETAILED DESCRIPTION OF THE INVENTION

The preferred embodiment of the present invention is detailed inFIG.3showing a cross dichroic prism coupled with three thin film solar cells. Solar radiation separation into spectral components and focusing on solar cells does not require the same level of optical precision as projectors allowing the rearrangement of dichroic film application in the present invention for ease of manufacturing. Specifics of dichroic film application to a particular prism sub-section would be determined as part of the manufacturing process. As an example manufacturing process, the following steps could be used to construct theFIG.3preferred embodiment. Lens100is formed as part of prism section10aused to focus the incident solar radiation onto the dichroic prism structure. Low Band Filter Film108aand High Band Filter Film110bare deposited onto prism section10aduring manufacture. Low Band Filter Film108band High Band Filter Film110aare deposited onto prism section10cduring manufacture. High Band Thin Film Solar Cell106is deposited onto prism section10dduring manufacture. Low Band Thin Film Solar Cell102is deposited onto prism section10bduring manufacture. Mid Band Thin Film Solar Cell104is deposited onto prism section10cduring manufacture. The four prism sections with composite filters and/or solar cells are adhered together using a transparent adhesive at interface points12aand12b. Prism sections10athrough10dcan be made using any UV transparent material for example but not limited to glass, acrylic or poly carbonate. As an example of solar spectrum separation, High Band Dichroic Filter Film110aand110bcan be designed to reflect visible wave lengths above 500 nm. Similarly, Low Band Dichroic Filter Film108aand108bcan be designed to reflect NIR wave lengths below 800 nm. Three different band gap matched thin film cells are required to cover the separated solar radiation components. Example solar cells for each component are, Low Band Thin Film Solar Cell102is a Perovskite for 350-790 nm, Mid Band Thin Film Solar Cell104is a CdTe for 500-850 nm and High Band Thin Film Solar Cell106is a CIGS for 550-1100 nm. This combination of thin film cells can effectively capture solar all energy covering the 300 nm to 1100 nm visible NIR spectrum.

FIG.4details the operation of the present invention cross dichroic prism on incident solar radiation serving to separate the spectrum into three components: high, mid, and low bands. The Incident Solar Radiation200is captured by focusing Lens202to concentrate angular solar radiation into the prism structure. Reflecting Surface208redirects the high band solar radiation spectrum component towards High Band Solar Cell206. Reflecting Surface214redirects the low band solar radiation spectrum component towards Low Band Solar Cell216. The mid band solar radiation spectrum component is transmitted through the prism towards Mid Band Solar Cell212. The three types of solar cells for each band are band gap matched to provide efficient power conversion.

An alternate embodiment would simplify the manufacturing complexity of prism section10cby placing Mid Band Solar Cell104onto a separate substrate. In this manner, prism section10conly requires the two dichroic films to be deposited. The separate substrate containing Mid Band Solar Cell104would be adhesively attached to prism section10cis a separate later assembly step.

Another alternate embodiment would be constructed with each solar cell102,104and106deposited onto a separate substrate and adhesively attached to the prism structure. This construction method serves to eliminate the requirement for direct thin film depositing of the solar cells onto the prism sub-sections.

FIG.5details the physical structure of an elongated prism assembly serving as a solar panel sub module. The cross dichroic prism structure combined with three spectrum component solar cells described inFIG.3is elongated length wise as shown inFIG.5310to form a fixed length assembly. The cross section of the prism structure is maintained for the entire elongated lengthFIG.5310of the sub module. As an example, method of fabrication, the following steps would be performed referencingFIG.3cross sectional elements for clarity. Initially, each section of the Cross Dichroic PrismFIG.5308would be formed from drawn or cut material at the elongated lengthFIG.5310required for the sub module. The focal LensFIG.5300is formed as part of the prism sectionFIG.310acovering the entire lengthFIG.5310of the sub module. Next, Dichroic Filter FilmsFIG.3108and110are deposited onto prism sectionsFIG.310aand10cfor the entire assembly elongated lengthFIG.5310. Following this, High Band Solar CellFIG.3106is deposited onto prism sectionFIG.310d, Low Band Solar CellFIG.3102is deposited onto prism sectionFIG.310band Mid Band Solar CellFIG.3104is deposited onto prism sectionFIG.310c. The solar cells, due to the substrate surface provided by each prism, can be implemented as either a continuous element or a group of separate elements depending on process requirements. The continuous or group of solar cells extends the entire elongated lengthFIG.5310of the sub module. The three solar cells (group or continuous) are shown asFIG.5306for Low Band,FIG.5304for Mid Band andFIG.5302for High Band extending the lengthFIG.5310of the sub module. After each prism section is complete, the four prism sections are assembled with AdhesiveFIG.312to complete the cross dichroic prism assembly of the sub module. Electrical connection to each solar cell can be achieved by fabricating contacts at the end point of the sub module.

FIG.6shows an example physical structure of a planer solar array or panel constructed from multiple sub modules. AlthoughFIG.6depicts ten sub modules, the final size of the completed solar array depends on the fixed length design of a sub module and the number of sub modules used within the array. Various differently sized panels can be fabricated by proper design selection of sub module length and number in the array. The Solar Panel Frame400is designed to provide mounting to hold the sub modules in place within a rigid form factor. AlthoughFIG.6depicts a planar structure, the form factor can take on any curved shape based on the design concept of frame400. The array of Solar Panel Sub Modules402is securely held within the frame aligned with the focal lens pointing upward thereby being clear of solar radiation blockage obstructions. Each Solar Panel Sub Module is electrically connected to a Power Conversion Electronics404unit serving to couple the solar panel into a larger electrical system.