System and method for solar energy capture and related method of manufacturing

Abstract

A system and method of capturing solar energy, and related method of manufacturing, are disclosed. In at least one embodiment, the system includes a first lens array having a plurality of lenses, and a first waveguide component adjacent to the lens array, where the waveguide component receives light, and where the waveguide component includes an array of prism/mirrored facets arranged along at least one surface of the waveguide component. The system further includes at least one photovoltaic cell positioned so as to receive at least a portion of the light that is directed out of the waveguide. A least some of the light passing into the waveguide component is restricted from leaving the waveguide component upon being reflected by at least one of the prism/mirrored facets, hereby the at least some light restricted from leaving the waveguide component is directed by the waveguide toward the at least one photovoltaic cell.

1 . A system for capturing solar energy, the system comprising:
 a first lens array having a plurality of lenses;   a second lens array, wherein the second lens array has a mirrored surface and wherein each of the lenses of the second lens array is aligned with a respective one of the lenses of the first lens array such that light received by the system for capturing solar energy is partially focused upon passing through the first lens array and further focused upon reflection from the second lens array to form a focal spot on a plane that lies between the first and the second lens arrays.   
     
     
         2 . The system of  claim 1 , further comprising an optical waveguide layer located between the first lens array and the second lens array, wherein the optical waveguide layer includes an array of injection features wherein each of the injection features is positioned to receive reflected light from at least one of the lenses of the second lens array and to direct the reflected light to the optical waveguide layer. 
     
     
         3 . The system of  claim 2 , wherein each injection feature is triangular in cross section, with at least one reflective surface that directs the reflected light in the optical waveguide layer. 
     
     
         4 . The system of  claim 2 , wherein the optical waveguide layer is separated from the first lens array by a first cladding layer and is separated from the second lens array by a second cladding layer. 
     
     
         5 . The system of  claim 2 , wherein each of the injection features is located at or near a focal spot of a lens of the second lens array, and wherein each injection feature is oriented so that at least some of the reflected light is coupled into the optical waveguide layer. 
     
     
         6 . The system of  claim 2 , wherein at least some of the light directed to the optical waveguide layer is guided within the optical waveguide layer by total internal reflection. 
     
     
         7 . The system of  claim 2 , wherein the optical waveguide layer is laterally shiftable relative to the first or the second lens arrays so that incident light arriving at the system for capturing solar energy is received by the injection features upon reflection from the second lens array even though an angle of incidence of the incident light arriving at the system for capturing solar energy varies with time. 
     
     
         8 . The system of  claim 7 , further comprising one or more actuators and a controller that adjusts a position of the optical waveguide layer relative to the first lens array and the second lens array to enable alignment of the injection features with the foci of the light reflected from the second lens array. 
     
     
         9 . The system of  claim 7 , further comprising one or more sensors that detect the angle of incidence of the incident light and provide a signal to the controller. 
     
     
         10 . A method of manufacturing a solar energy collection system, comprising:
 providing a first lens array;   providing a second lens array with a mirrored coating;   molding a prism array from an ultra-violet-curable polymer film;   positioning the prism array between the first and second lens arrays.   
     
     
         11 . The method of  claim 10 , further comprising:
 providing one or more cladding films having lower refractive index than the first lens array or the second lens array; and   placing the one or more cladding films between the prism array and the first lens array or the second lens array to form a light-guide.   
     
     
         12 . The method of  claim 10 , further comprising: depositing a reflective coating on facets of the prism array. 
     
     
         13 . The method of  claim 10 , further comprising: crosslinking specific portions of the ultraviolet-curable polymer film by exposing the first or the second lens arrays and the prism array to ultraviolet light and subsequently rinsing the first or the second lens arrays and the prism array in a solvent to remove uncured polymer material. 
     
     
         14 . The method of  claim 13 , wherein the ultraviolet light is directed through the first lens array or the second lens array.