New concepts and techniques for the development of high-efficiency concentrating photovoltaic modules

El interés por los sistemas fotovoltaicos de concentración (CPV) ha resurgido en los últimos años amparado por el desarrollo de células multiunión de muy alta eficiencia basadas en semiconductores de los grupos III-V. Estas células han permitido obtener módulos de concentración con eficiencias que prácticamente duplican las del panel plano y que llegan al 35% en los módulos récord. Esta tesis está dedicada al diseño y la implementación experimental de nuevos conceptos que permitan obtener módulos CPV que no sólo alcancen una eficiencia alta en condiciones estándar sino que, además, sean lo suficientemente tolerantes a errores de montaje, seguimiento, temperatura y variaciones espectrales para que la energía que producen a lo largo del año sea máxima. Una de las primeras cuestiones que se abordan es el diseño de elementos ópticos secundarios para sistemas cuyo primario es una lente de Fresnel y que permiten, para una concentración fija, aumentar el ángulo de aceptancia y la tolerancia del sistema. Varios secundarios reflexivos y refractivos han sido diseñados y analizados mediante trazado de rayos. En particular, utilizando óptica anidólica y basándose en el diseño de una sola etapa conocido como ‘concentrador dieléctrico que funciona por reflexión total interna‘, se ha diseñado, fabricado y caracterizado un secundario con salida cuadrada que, usado junto con una lente de Fresnel, permite alcanzar simultáneamente una elevada eficiencia, concentración y aceptancia. Además, se ha propuesto y prototipado un método alternativo de fabricación para otro de los secundarios, denominado domo, consistente en el sobremoldeo de silicona sobre células solares. Una de las características que impregna todo el trabajo realizado en esta tesis es la aproximación holística en el diseño de módulos CPV, es decir, se ha prestado especial atención al diseño conjunto de la célula y la óptica para garantizar que el sistema total alcance la mayor eficiencia posible. En este sentido muchos sistemas ópticos desarrollados en esta tesis han sido diseñados, caracterizados y optimizados teniendo en cuenta que el ajuste de corriente entre las distintas subcélulas que comprenden la célula multiunión bajo el concentrador sea muy próximo a uno. La capa antirreflectante sobre la célula funciona, en cierto modo, como interfaz entre la óptica y la célula, por lo que se ha diseñado un método de optimización de capas antirreflectantes que considera no sólo el amplio rango de longitudes de onda para el que las células multiunión son sensibles sino también la distribución angular de intensidad sobre la célula creada por la óptica de concentración. Además, la cuestión de la falta de uniformidad también se ha abordado mediante la comparación de las distribuciones espectrales y espaciales de irradiancia que crean diferentes ópticas (simuladas mediante trazado de rayos y fotografiadas) y las pérdidas de eficiencia que experimentan las células iluminadas por dichas ópticas de concentración medidas experimentalmente. El efecto de la temperatura en la óptica de concentración también ha sido objeto de estudio de esta tesis. En particular, mediante simulaciones de elementos finitos se han dado los primeros pasos para el análisis de las deformaciones que sufren los dientes de las lentes de Fresnel híbridas (vidrio-silicona), así como el cambio de índice de refracción con la temperatura y la influencia de ambos efectos sobre el funcionamiento de los sistemas. Se ha implementado un modelo que tiene por objeto considerar las variaciones ambientales, principalmente temperatura y contenido espectral de la radiación directa, así como las sensibilidades térmica y espectral de los sistemas CPV, con el fin de maximizar la energía producida por un módulo de concentración a lo largo de un año en un emplazamiento determinado. Los capítulos 5 y 6 de este libro están dedicados al diseño, fabricación y caracterización de un nuevo concepto de módulo fotovoltaico denominado FluidReflex y basado en una única etapa reflexiva con dieléctrico fluido. En este nuevo concepto la presencia del fluido aporta algunas ventajas significativas como son: un aumento del producto concentración por aceptancia (CAP, en sus siglas en inglés) alcanzable al rodear la célula con un medio cuyo índice de refracción es mayor que uno, una mejora de la eficiencia óptica al disminuir las pérdidas por reflexión de Fresnel en varias interfaces, una mejora de la disipación térmica ya que el calor que se concentra junto a la célula se trasmite por convección natural y conducción en el fluido y un aislamiento eléctrico mejorado. Mediante la construcción y medida de varios prototipos de unidad elemental se ha demostrado que no existe ninguna razón fundamental que impida la implementación práctica del concepto teórico alcanzando una elevada eficiencia. Se ha realizado un análisis de fluidos candidatos probando la existencia de al menos dos de ellos que cumplen todos los requisitos (en particular el de estabilidad bajo condiciones de luz concentrada) para formar parte del sistema de concentración FluidReflex. Por ´ultimo, se han diseñado, fabricado y caracterizado varios prototipos preindustriales de módulos FluidReflex para lo cual ha sido necesario optimizar el proceso de fabricación de la óptica multicavidad a fin de mantener el buen comportamiento óptico obtenido en la fabricación de la unidad elemental. Los distintos prototipos han sido medidos, tanto en el laboratorio como bajo el sol real, analizando el ajuste de corriente de la célula iluminada por el concentrador FluidReflex bajo diferentes distribuciones espectrales de la radiación incidente así como el excelente comportamiento térmico del módulo. ABSTRACT A renewed interest in concentrating photovoltaic (CPV) systems has emerged in recent years encouraged by the development of high-efficiency multijunction solar cells based in IIIV semiconductors that have led to CPV module efficiencies which practically double that of flat panel PV and which reach 35% for record modules. This thesis is devoted to the design and experimental implementation of new concepts for obtaining CPV modules that not only achieve high efficiency under standard conditions but also have such a wide tolerance to assembly errors, tracking, temperature and spectral variations, that the energy generated by them throughout the year is maximized. One of the first addressed issues is the design of secondary optical elements whose primary optics is a Fresnel lens and which, for a fixed concentration, allow an increased acceptance angle and tolerance of the system. Several reflective and refractive secondaries have been designed and analyzed using ray tracing. In particular, using nonimaging optics and based on the single-stage design known as ‘dielectric totally internally reflecting concentrator’, a secondary with square output has been designed, fabricated and characterized. Used together with a Fresnel lens, the secondary can simultaneously achieve high efficiency, concentration and acceptance. Furthermore, an alternative method has been proposed and prototyped for the fabrication of the secondary named dome. The optics is manufactured by direct overmolding of silicone over the solar cells. One characteristic that permeates all the work done in this thesis is the holistic approach in the design of CPV modules, meaning that special attention has been paid to the joint design of the solar cell and the optics to ensure that the total system achieves the highest attainable efficiency. In this regard, many optical systems developed in the thesis have been designed, characterized and optimized considering that the current matching among the subcells within the multijunction solar cell beneath the optics must be close to one. Antireflective coating over the cell acts, somehow, as an interface between the optics and the cell. Consequently, a method has been designed to optimize antireflective coatings that takes into account not only the broad wavelength range that multijunction solar cells are sensitive to but also the angular intensity distribution created by the concentrating optics. In addition, the issue of non-uniformity has also been addressed by comparing the spectral and spatial distributions of irradiance created by different optics (simulated by ray tracing and photographed) and the efficiency losses experienced by cells illuminated by those concentrating optics experimentally determined. The effect of temperature on the concentrating optics has also been studied in this thesis. In particular, finite element simulations have been use to analyze the deformations experienced by the facets of hybrid (silicon-glass) Fresnel lenses, the change of refractive index with temperature and the influence of both effects on the system performance. A model has been implemented which take into consideration atmospheric variations, mainly temperature and spectral content of the direct normal irradiance, as well as thermal and spectral sensitivities of systems, with the aim of maximizing the energy harvested by a CPV module throughout the year in a particular location. Chapters 5 and 6 of this book are devoted to the design, fabrication, and characterization of a new concentrator concept named FluidReflex and based on a single-stage reflective optics with fluid dielectric. In this new concept, the presence of the fluid provides some significant advantages such as: an increased concentration acceptance angle product (CAP) achievable by surrounding the cell with a medium whose refractive index is greater than one, an improvement of the optical efficiency by reducing losses due to Fresnel reflection at several interfaces, an improvement in heat dissipation as the heat concentrated near the cell is transmitted by natural convection and conduction in the fluid, and an improved electrical insulation. By fabricating and characterizing several elementary-unit prototypes it was shown that there is no fundamental reason that prevents the practical implementation of this theoretical concept reaching high efficiency. Several fluid candidates were investigated proving the existence of at least to fluids that meet all the requirements (including the stability under concentrated light) to become part of the FluidReflex concentrator. Finally, several pre-industrial FluidReflex module prototypes have been designed and fabricated. An optimization process for the manufacturing of the multicavity optics was necessary to attain such an optics quality as the one achieved by the single unit. The module prototypes have been measured, both indoors and outdoors, analyzing the current matching of the solar cells beneath the concentrator for different spectral distribution of the incident irradiance. Additionally, the module showed an excellent thermal performance.

Materials Research for HiPER Laser Fusion Facilities: Chamber Wall, Structural Material and Final Optics

The European HiPER project aims to demonstrate commercial viability of inertial fusion energy within the following two decades. This goal requires an extensive Research &Development program on materials for different applications (e.g., first wall, structural components and final optics). In this paper we will discuss our activities in the framework of HiPER to develop materials studies for the different areas of interest. The chamber first wall will have to withstand explosions of at least 100 MJ at a repetition rate of 5-10 Hz. If direct drive targets are used, a dry wall chamber operated in vacuum is preferable. In this situation the major threat for the wall stems from ions. For reasonably low chamber radius (5-10 m) new materials based on W and C are being investigated, e.g., engineered surfaces and nanostructured materials. Structural materials will be subject to high fluxes of neutrons leading to deleterious effects, such as, swelling. Low activation advanced steels as well as new nanostructured materials are being investigated. The final optics lenses will not survive the extreme ion irradiation pulses originated in the explosions. Therefore, mitigation strategies are being investigated. In addition, efforts are being carried out in understanding optimized conditions to minimize the loss of optical properties by neutron and gamma irradiation

Advances in the SMS design method for imaging optics

In this work, two SMS algorithms are presented for an objective design with different selected ray-bundles: three meridian ray-bundles (3M) and one meridian and two skew ray-bundles (1M-2S), the latter from pin hole point of view, provides a better sampling of the phase space. Results obtained with different algorithms will be compared.

Integrating tracking in concentrating photovoltaics using laterally moving optics

In this work the concept of integrating tracking in concentrating photovoltaics is briefly summarized and possible fields of application are classified. A previously proposed system setup relies on the use of two rotational symmetric laterally moving plano-convex lenses to achieve 500× concentration over an angular range of ±24 ◦ . However, the circular lens apertures are less suitable for application in lens array structures. A new design algorithm based on the Simultaneous Multiple Surface algorithm in three dimensions (SMS3D) demonstrates the ability to address this problem. Performance simulations show that the resulting non-rotational symmetric design outperforms its conventional rotational symmetric counterpart

Progress in the SMS design method for imaging optics

In this work, two SMS algorithms are presented for an objective design with different selected ray-bundles: three meridian ray-bundles (3M) and one meridian and two skew ray-bundles (1M-2S), the latter from pin hole point of view, provides a better sampling of the phase space. Results obtained with different algorithms will be compared

Overview of the SMS design method applied to imaging optics

The Simultaneous Multiple Surfaces (SMS) was developed as a design method in Nonimaging Optics during the 90s. Later, the method was extended for designing Imaging Optics. We present an overview of the method applied to imaging optics in planar (2D) geometry and compare the results with more classical designs based on achieving aplanatism of different orders. These classical designs are also viewed as particular cases of SMS designs. Systems with up to 4 aspheric surfaces are shown. The SMS design strategy is shown to perform always better than the classical design (in terms of image quality). Moreover, the SMS method is a direct method, i.e., it is not based in multi-parametric optimization techniques. This gives the SMS method an additional interest since it can be used for exploring solutions where the multiparameter techniques can get lost because of the multiple local minima

Optics detailed analysis of an improved collimation system for LED light sources

Optics detailed analysis of an improved collimation system for LED light sources

The Dome-Shaped Fresnel-Köhler Concentrator

Manufacturing tolerances, along with a high concentration ratio, are key issues in order to obtain cheap CPV systems for mass production. Consequently, this manuscript presents a novel tolerant and cost effective concentrator optic: the domed-shaped Fresnel-Köhler, presenting a curved Fresnel lens as Primary Optical Element (POE). This concentrator is based on two previous successful CPV designs: the FK concentrator, based on a flat Fresnel lens, and the dome-shaped Fresnel lens system developed by Daido Steel, resulting on a superior concentrator. The manuscript shows outstanding simulation results for geometrical concentration factor of Cg? = ?1,230x: high tolerance and high optical efficiency, achieving acceptance angles of 1.18° (dealing to a CAP?=0.72) and efficiencies over 85% (without any anti-reflective coating). Moreover, Köhler integration provides good irradiance uniformity on the cell surface without increasing system complexity by means of any extra element. Daido Steel advanced technique for demolding injected plastic pieces will allow for easy manufacture of the dome-shaped POE of DFK concentrator.

Photovoltaic performance of the dome-shaped Fresnel-Köhler concentrator

In order to have a cost-effective CPV system, two key issues must be ensured: high concentration factor and high tolerance. The novel concentrator we are presenting, the dome-shaped Fresnel-Köhler, can widely fulfill these two and other essential issues in a CPV module. This concentrator is based on two previous successful CPV designs: the FK concentrator with a flat Fresnel lens and the dome-shaped Fresnel lens system developed by Daido Steel, resulting on a superior concentrator. The concentrator has shown outstanding simulation results, achieving an effective concentration-acceptance product (CAP) value of 0.72, and an optical efficiency of 85% on-axis (no anti-reflective coating has been used). Moreover, Köhler integration provides good irradiance uniformity on the cell surface and low spectral aberration of this irradiance. This ensures an optimal performance of the solar cell, maximizing its efficiency. Besides, the dome-shaped FK shows optimal results for very compact designs, especially in the f/0.7-1.0 range. The dome-shaped Fresnel-Köhler concentrator, natural and enhanced evolution of the flat FK concentrator, is a cost-effective CPV optical design, mainly due to its high tolerances. Daido Steel advanced technique for demolding injected plastic pieces will allow for easy manufacture of the dome-shaped POE of DFK concentrator.

Beam-steering array optics with the SMS method

In this work, a new design concept of SMS moving optics is developed, in which the movement is no longer lateral but follows a curved trajectory calculated in the design process. Curved tracking trajectory helps to broaden the incident angle?s range significantly. We have chosen an afocal-type structure which aim to direct the parallel rays of large incident angles to parallel output rays. The RMS of the divergence angle of the output rays remains below 1 degree for an incident angular range of ±450. Potential applications of this beam-steering device are: skylights to provide steerable natural illumination, building integrated CPV systems, and steerable LED illumination.

Primary optics for efficient high-brightness LED color mixing

In SSL general illumination, there is a clear trend to high flux packages with higher efficiency and higher CRI addressed with the use of multiple color chips and phosphors. However, such light sources require the optics provide color mixing, both in the near-field and far-field. This design problem is specially challenging for collimated luminaries, in which diffusers (which dramatically reduce the brightness) cannot be applied without enlarging the exit aperture too much. In this work we present first injection molded prototypes of a novel primary shell-shaped optics that have microlenses on both sides to provide Köhler integration. This shell is design so when it is placed on top of an inhomogeneous multichip Lambertian LED, creates a highly homogeneous virtual source (i.e, spatially and angularly mixed), also Lambertian, which is located in the same position with only small increment of the size (about 10-20%, so the average brightness is similar to the brightness of the source). This shell-mixer device is very versatile and permits now to use a lens or a reflector secondary optics to collimate the light as desired, without color separation effects. Experimental measurements have shown optical efficiency of the shell of 95%, and highly homogeneous angular intensity distribution of collimated beams, in good agreement with the ray-tracing simulations.

Novel lateral moving tracking optics with the SMS design method

Lateral moving optics along straight path has already been studied in the past. However, their relative small angular range can be a limitation to potential applications. In this work, a new design concept of SMS moving optics is developed, in which the movement is no longer lateral but follows a curved trajectory, which is calculated in the design process. We have chosen an afocal system, which aim to direct the parallel rays of large incident angles to parallel output rays, and we have obtained that the RMS of the divergence angle of the output rays remains below 1 degree within a input angular range of ±45 output. Potential applications of this beam-steering device are: skylights to provide steerable natural illumination, building integrated CPV systems, and steerable LED illumination.

Plasmonic nanoparticles for the protection of the final optics in inertial confinement fusion facilities: capabilities and limitations

Final lenses in laser fusion plants. Challenges for the protection of the final lenses. Plasmonic nanoparticles. Radiation resistance

The Ventana Optical Train: a high-performance off-the-shelf HCPV optics solution

- PV and HCPV compete in the utility market - PV cost reduction has been dramatic through volume - A complete off-the-shelf optics solution by Evonik and LPI - Based on the best-in-class design: The FK concentrator

1000x shadow-free mirror-based Köhler concentrator

A new design for a photovoltaic concentrator, the most recent advance based on the Kohler concept, is presented. The system is mirror-based, and with geometry that guaranties a maximum sunlight collection area (without shadows, like those caused by secondary stages or receivers and heat-sinks in other mirror-based systems). Designed for a concentration of 1000x, this off axis system combines both good acceptance angle and good irradiance uniformity on the solar cell. The advanced performance features (concentration-acceptance products ?CAP- about 0.73 and affordable peak and average irradiances) are achieved through the combination of four reflective folds combined with four refractive surfaces, all of them free-form, performing Köhler integration 2 . In Köhler devices, the irradiance uniformity is not achieved through additional optical stages (TIR prisms), thus no complex/expensive elements to manufacture are required. The rim angle and geometry are such that the secondary stage and receivers are hidden below the primary mirrors, so maximum collection is assured. The entire system was designed to allow loose assembly/alignment tolerances (through high acceptance angle) and to be manufactured using already well-developed methods for mass production, with high potential for low cost. The optical surfaces for Köhler integration, although with a quite different optical behavior, have approximately the same dimensions and can be manufactured with the same techniques as the more traditional secondary optical elements used for concentration (typically plastic injection molding or glass molding).