Thermal spray for solar concentrator fabrication

Abstract

A system may include an optical element, a thermal-sprayed material disposed on the optical element, and a solar cell coupled to the optical element. Some aspects provide thermal spraying of a first material onto an optical element, and coupling of a solar cell to the optical element. Thermal spraying the first material may include spraying a molten metal powder onto the optical element.

1 . A method comprising:
 thermal spraying a first material onto an optical element; and   coupling a solar cell to the optical element.   
     
     
         2 . A method according to  claim 1 , wherein thermal spraying the first material comprises spraying a molten metal powder onto the optical element. 
     
     
         3 . A method according to  claim 2 , wherein spraying the molten metal powder onto the optical element comprises:
 placing a stencil on the optical element; and   spraying a molten metal powder onto the stencil and the optical element.   
     
     
         4 . A method according to  claim 3 , further comprising:
 removing the stencil to expose an aperture from which light may pass out of the optical element,   wherein coupling the solar cell to the optical element comprises:   coupling an electrical contact of the solar cell to the first material to align an optically-active area of the solar cell with the aperture.   
     
     
         5 . A method according to  claim 3 , wherein the stencil comprises a mechanical, hard or soft tooling. 
     
     
         6 . A method according to  claim 1 , wherein thermal spraying the first material comprises powder coating a polymer onto the optical element. 
     
     
         7 . A method according to  claim 1 , further comprising:
 depositing a reflective material on a substantially-transparent core; and   depositing an insulator on the reflective material;   wherein thermal spraying the first material comprises spraying a molten metal powder onto the insulator.   
     
     
         8 . A method according to  claim 7 , wherein depositing the insulator comprises powder coating a polymer onto the reflective material. 
     
     
         9 . A method according to  claim 7 , wherein depositing the reflective material comprises physical vapor deposition of the reflective material onto the substantially-transparent core. 
     
     
         10 . A method according to  claim 7 , wherein thermal spraying the first material comprises:
 placing a stencil on the insulator; and   spraying a molten metal powder onto the stencil and the insulator.   
     
     
         11 . A method according to  claim 1 , wherein thermal spraying the first material onto the optical element comprises:
 placing a stencil on the optical element; and   spraying the first material onto the stencil and the optical element.   
     
     
         12 . A method according to  claim 1 , wherein coupling the solar cell to the optical element comprises coupling an electrical contact of the solar cell to the first material to align an optically-active area of the solar cell with an aperture from which light may pass out of the optical element. 
     
     
         13 . An apparatus comprising:
 an optical element;   a thermal-sprayed material disposed on the optical element; and   a solar cell coupled to the optical element.   
     
     
         14 . An apparatus according to  claim 13 , wherein the thermal-sprayed material comprises a hardened metal powder. 
     
     
         15 . An apparatus according to  claim 14 , wherein:
 the optical element comprises an aperture from which light may pass out of the optical element,   an electrical contact of the solar cell is coupled to the hardened metal powder, and   an optically-active area of the solar cell is aligned with the aperture.   
     
     
         16 . An apparatus according to  claim 13 , wherein the thermal-sprayed material comprises a polymer. 
     
     
         17 . An apparatus according to  claim 13 , wherein the optical element comprises:
 a substantially-transparent core;   a reflective material disposed on the substantially-transparent core; and   an insulator disposed on the reflective material,   wherein the thermal-sprayed material is disposed on the insulator.   
     
     
         18 . An apparatus according to  claim 17 , wherein the insulator comprises a powder-coated polymer. 
     
     
         19 . An apparatus according to  claim 13 , wherein:
 the optical element comprises an aperture from which light may pass out of the optical element,   an electrical contact of the solar cell is coupled to the thermal-sprayed material, and   an optically-active area of the solar cell is aligned with the aperture.