Laminate structure with embedded cavities for use with solar cells and related method of manufacture

Abstract

An integrated laminate structure adapted for application in the context of solar technology, including a first carrier element, optionally including optically substantially transparent material enabling light transmission therethrough, a second carrier element provided with at least one surface relief pattern including a number of surface relief forms and having at least one predetermined optical function relative to incident light, the second carrier element including optically substantially transparent material enabling light transmission therethrough, the first and second carrier elements being laminated together such that the at least one surface relief pattern has been embedded within the established laminate structure and a number of related cavities have been formed at the interface of the first and second carrier elements. An applicable method of manufacture.

1 . An integrated laminate structure adapted for application in the context of solar technology, the integrated laminate structure comprising:
 a first carrier element, optionally comprising optically substantially transparent material enabling light transmission therethrough, and   a second carrier element provided with at least one surface relief pattern comprising a number of surface relief forms and having at least one predetermined optical function relative to incident light, said second carrier element comprising optically substantially transparent material enabling light transmission therethrough,   wherein the first and second carrier elements are laminated together such that the at least one surface relief pattern has been embedded within the established laminate structure and a number of related, optically functional cavities have been formed at the interface of said first and second carrier elements.   
     
     
         2 . The integrated laminate structure according to  claim 1 , wherein a cavity formed within the laminate comprises fluid or solid different from the material of the secand and optionally first carrier element. 
     
     
         3 . The integrated laminate structure according to  claim 1 , wherein a cavity formed comprises substantially air or other gaseous medium. 
     
     
         4 . The integrated laminate structure according to  claim 1 , wherein a cavity formed comprises liquid or gel. 
     
     
         5 . The integrated laminate structure according to  claim 1 , wherein said second carrier element is a substantially a film, optionally being a bendable film. 
     
     
         6 . The integrated laminate structure according to  claim 1 , further comprising:
 a functional, optionally optically functional, film.   
     
     
         7 . The integrated laminate structure according to  claim 1 , wherein the embedded surface relief pattern is configured to couple incident light, the incident angles coupled optionally defining a total range of at least about  130  degrees, the embedded surface relief pattern being configured to couple the incident light with a collimation function substantially towards a predetermined direction of a solar cell. 
     
     
         8 . The integrated laminate structure according to  claim 1 , further comprising:
 at least one element selected from the group consisting of: an embedded surface relief pattern or form configured for internal light trapping by back-coupling and/or redirecting light substantially back to the direction it arrived at the pattern or form from, and an embedded surface relief pattern or form configured for internal light coupling and/or redirecting optionally without reflective function.   
     
     
         9 . The integrated laminate structure according to  claim 1 , further comprising:
 at least partially embedded multilayer pattern of surface relief forms with a common function or at least jointly designed multiple functions, wherein the multilayer pattern may be established by one or more elements laminated together in the laminate structure.   
     
     
         10 . The integrated laminate structure according to  claim 1 , wherein the embedded surface relief pattern has at least one function selected from the group of: light directing function, light trapping function, reflective function, transmissive function, transreflective function, coupling function, incoupling function, outcoupling function, polarizing function, diffractive function, refractive function, anti-glare function, anti-clear function, anti-reflection function, collimating function, precollimation function, lens function, converging function, diverging function, wavelength modifying function, scattering function, coloring function, medium distribution function, and diffusing function. 
     
     
         11 . The integrated laminate structure according to  claim 1 , wherein at least one carrier element comprises at least one material selected from the group consisting of:
 plastic, elastomer, polymer, glass, semiconductor, silicon, adhesive, resin, and ceramic material.   
     
     
         12 . The integrated laminate structure according to  claim 1 , further comprising:
 a functional coating and/or surface structure such as a surface relief pattern.   
     
     
         13 . The integrated laminate structure according to  claim 12 , wherein the coating and/or surface structure has at least one function selected from the group consisting of: anti-reflection function, hydrophobic function, hydrophilic function, and self-cleaning function. 
     
     
         14 . The integrated laminate structure according to  claim 1 , further comprising:
 a plurality of forms in the embedded surface relief pattern of sub-micron size.   
     
     
         15 . The integrated laminate structure according to  claim 1 , wherein the surface relief pattern comprises at least one form selected from the group consisting of: a groove, a protrusion, a ridge, a recess, a binary form, a slanted form, a rectangular form, a quadratic form, a triangular form, a grating pixel form, a trapezoidal form, an isosceles trapezoidal form, and a lens form. 
     
     
         16 . A solar cell structure, comprising:
 the integrated laminate structure according to  claim 1 .   
     
     
         17 . The solar cell structure according to  claim 16 , further comprising:
 a semiconductor material-containing element provided with a surface relief pattern increasing the surface area thereof.   
     
     
         18 . The solar cell structure according to  claim 17 , wherein the surface relief pattern is configured to enhance light absorption into the material and/or to reduce reflections therefrom in order to raise the efficiency of the solar cell. 
     
     
         19 . An integrated laminate structure adapted for application in the context of solar technology, said integrated laminate structure comprising:
 at least two elements at least one of which, optionally both, comprising optically substantially transparent material and the elements being laminated together such that at least one surface relief pattern of either element has been embedded within the laminate structure.   
     
     
         20 . A system, comprising:
 a solar cell structure; and   a laminate structure according to  claim 1 , wherein the laminate structure is disposed on and optionally secured.   
     
     
         21 . A method for constructing an integrated structure for optical applications in the context of solar technology, such as a structure incorporating a solar cell or to be at least disposed over a solar cell, the method comprising:
 obtaining a first carrier element optionally comprising optically substantially transparent material enabling light transmission therethrough,   obtaining a second carrier element provided with at least one surface relief pattern comprising a number of surface relief forms and having at least one predetermined optical function relative to incident light, said second carrier element comprising optically substantially transparent material enabling light transmission therethrough, and   laminating, optionally in a roll-to-roll fashion, the first and second carrier elements together such that the at least one surface relief pattern is embedded within the established laminate structure and a number of cavities are formed at the interface of said first and second carrier elements.   
     
     
         22 . The method according to  claim 21 , wherein during manufacturing a master for surface relief production, a pre-master with a pattern of surface relief forms is established and the pattern is modulated to generate the master by inclusion of material in the pattern to fill a number of forms thereof and to therefore prevent their introduction to the master. 
     
     
         23 . The method according to  claim 21 , wherein a surface relief form is produced using at least one technique selected from the group consisting of: embossing, imprinting, lithography, molding, micro-molding, and casting. 
     
     
         24 . The method according to  claim 21 , wherein adhesive and/or curing is applied during the lamination and/or forming of the surface relief pattern. 
     
     
         25 . The method according to  claim 21 , wherein the second carrier element comprises or is provided with curable material that is adapted to host the at least one surface relief pattern.