METHOD OF MANUFACTURING PHOTOVOLTAIC (PV) ENHANCEMENT FILMS
First Claim
1. A method of manufacturing a photovoltaic (PV) enhancement film, comprising:
- providing an extrusion device comprising an embossing roller with a surface engraved with a contoured pattern corresponding to a plurality of absorption enhancement structures;
feeding a web of substantially transparent material at an extrusion temperature to the extrusion device; and
rolling the embossing roller against a first side of the web to form the plurality of absorption enhancement structures, wherein the absorption enhancement structures each comprise a light receiving surface that directs at least a portion of light that passes through a second side of the web toward the first side back toward the second side, wherein each of the absorption enhancement structures comprises an elongated body including at least two sides angled inward, whereby the absorption enhancement structures extend outward from a substrate provided by the web of substantially transparent material.
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Accused Products
Abstract
A method for manufacturing a photovoltaic (PV) enhancement film. The method includes providing an extrusion device with an embossing roller engraved to have a pattern corresponding to a set of absorption enhancement structures. The method includes feeding a web of substantially transparent material, such as an UV-stabilized blend of polycarbonate or acrylic. The method includes rolling the embossing roller against a first side of the web to form the absorption enhancement structures. The absorption enhancement structures each include a light receiving surface that directs at least a portion of light that passes through a second side of the web toward the first side back toward the second side (e.g., the structures may be configured to provide total internal reflection when applied to a PV device). The structures refract incident light to provide an average path length ratio of greater than about 1.10 in the PV device.
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Citations
37 Claims
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1. A method of manufacturing a photovoltaic (PV) enhancement film, comprising:
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providing an extrusion device comprising an embossing roller with a surface engraved with a contoured pattern corresponding to a plurality of absorption enhancement structures; feeding a web of substantially transparent material at an extrusion temperature to the extrusion device; and rolling the embossing roller against a first side of the web to form the plurality of absorption enhancement structures, wherein the absorption enhancement structures each comprise a light receiving surface that directs at least a portion of light that passes through a second side of the web toward the first side back toward the second side, wherein each of the absorption enhancement structures comprises an elongated body including at least two sides angled inward, whereby the absorption enhancement structures extend outward from a substrate provided by the web of substantially transparent material. - View Dependent Claims (2, 3, 4, 5, 6, 8, 9, 10, 14, 15, 16, 29)
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7. (canceled)
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12. (canceled)
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13. (canceled)
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17. A method of fabricating a photovoltaic apparatus with enhanced energy absorption, comprising:
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providing a layer of photovoltaic (PV) material that is positioned under a protective layer of substantially transparent material, wherein incident light striking the protective layer over a range of incidence angles has a first average path length through the PV material; fabricating a PV enhancement film including extruding a web of plastic through a set of rollers including a chilled embossing roller to form a plurality of absorption enhancement structures on a first side of the plastic web; applying a layer of adhesive to the second side of the plastic web; and attaching the plastic web to the protective layer opposite the PV material via the adhesive layer, wherein each of the absorption enhancement structures comprises a body shaped to transmit light incident upon an outer surface of the body toward the PV material at a differing angle than the incident light striking the protective layer and to direct at least a portion of light reflected from the PV material back toward the PV material using total internal reflection (TIR), wherein the light incident upon the body over the range of incidence angles has a second average path length that is at least about 10 percent greater than the first average path length. - View Dependent Claims (18, 19, 20, 21, 22, 23)
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24. A method of forming a photovoltaic (PV) enhancement film for use within a solar device with a light-receiving surface, comprising:
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providing a volume of substantially transparent material at an extrusion temperature above ambient temperature; and using a chilled embossing roller with a surface engraved with a pattern to form a plurality of absorption enhancement structures on a light receiving surface of a sheet of the substantially transparent material, wherein each of the absorption enhancement structures comprises at least one facet for receiving incident light on the light receiving surface, for directing the incident light toward the light-receiving surface of the solar device when placed proximate to the solar device whereby a path length in PV material of the solar device is greater than a base path length determined in an absence of the PV enhancement film, and for reflecting a portion of light reflected from the light-receiving surface of the solar device. - View Dependent Claims (25, 26, 27, 28)
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30. A method of manufacturing a photovoltaic (PV) enhancement film, comprising:
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providing an extrusion device comprising an embossing roller with a surface engraved with a contoured pattern corresponding to a plurality of absorption enhancement structures; feeding a web of substantially transparent material at an extrusion temperature to the extrusion device; and rolling the embossing roller against a first side of the web to form the plurality of absorption enhancement structures, wherein the absorption enhancement structures each comprise a light receiving surface that directs at least a portion of light that passes through a second side of the web toward the first side back toward the second side, wherein the light receiving surface refracts incident light striking the first side to provide an average path length ratio of greater than about 1.10 when the embossed web is applied over a layer of PV material over a range of incidence angles. - View Dependent Claims (31, 32, 33, 34, 35, 36, 37)
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Specification