Freeform micro-optical arrays (FMOAs) can overcome some limitations of rotationally symmetric optical components. The manufacturability assessment for FMOA designs containing many freeform elements is demanding. We present computer-aided design (CAD) tools that analyze FMOA designs for manufacturing constraints. They 1) extract the height (Sag) and 2) local slope while highlighting areas beyond manufacturing limits, 3) extract the minimum tool radius and 4) convert CADs into ray traceable solids using NURBS for performance comparison of the actual micro-structure to the design. Critical parameters can be identified early, reducing time-consuming and costly adjustments later.
Most virtual reality (VR) headsets nowadays use conventional, rotationally symmetric optics to create a wide field of view
(FOV > 90°) virtual scene enabling the required “immersion” or “presence” feeling. These optics require a long total track
length (TTL, distance between the actual panel displaying the contents and user’s pupil) to work well, and headsets become
very bulky. The so-called CLOVER is an optic, compatible with VR and video-see-through mixed reality (MR) able to
work around the TTL problem by using a freeform multi-channel, light folding approach. In its simplest version, it can
reduce the TTL down to a half, compared to conventional solutions, for the same FOV and angular resolution. Along with
a review of the original 4-channel CLOVER, this work shows recent results of upscale versions of the optic that utilize
myopia and color correction, pupil tracking and staggered surfaces to, respectively, avoid the need of prescription lenses,
improve the image quality for all colors, rise the resolution (by a 20%) and reduce the size (20% TTL reduction) of the
precursor.
Free-form micro-optical arrays (FMOAs) gain increasing interest because they can overcome some limitations of rotationally symmetric optical components and because of the benefits of their microscopic dimensions. They enable better performance and compactness of optical devices. However, the complex and segmented surface shapes bring many challenges, from design to fabrication to quality control. In particular, for FMOA designs that contain many individual free-form elements, their manufacturability assessment is far from trivial. Here, we present computer-aided design (CAD)-based tools that analyze FMOA designs for manufacturing constraints so that critical parts can be identified at an early stage, reducing time-consuming and costly adjustments at a later stage. The CAD tools are of great support to quickly and reliably analyze FMOA designs containing several hundred individual elements in an automated manner. They have been developed as user-oriented tools that require little software knowledge and display the results with great visual clarity
Reducing the size of Virtual Reality head-mounted displays is of main interest to improve the comfort of users, which is a particularly complex design problem due to the very large field of view needed to feel the immersion. High compactness with high transmission efficiency and high contrast can be achieved by multichannel optics, whose design for high performance is carried out at LIMBAK introducing intensively freeform optical surfaces, increased resolution via variable magnification, dynamic mapping control and super-sampling via pixel interlacing. This presentation will cover the growing variety of geometries, how to address their challenges and envision their future.
Reducing the size of Virtual Reality head-mounted displays is of main interest to improve the comfort of users, which is a particularly complex design problem due to the very large field of view needed to feel the immersion. Such reduction can be achieve via folded polarization “pancake” optics, but at the expense of a very low transmission efficiency and poor contrast. High compactness without those drawbacks can be achieved by multichannel optics, whose design for high performance is carried out at LIMBAK intensively introducing freeform optical surfaces, adding variable magnification to maximize the VR display resolution where it is to be normally gazed, and applying two-dimensional distortion software corrections to each channel. This presentation will cover the recent advances in these systems, the growing variety of geometries, the benefits obtained when including gaze-tracking and the resolution boosts obtained by the application of pixel interlacing strategies.
Compared to conventional, rotationally-symmetric optics, free-form optics provide additional degrees of freedom that enable special geometrical and performance features. For instance, in AR and VR, some approaches based on free-forms have shown their ability to reduce the display to pupil distance (total track length, or TTL), to increase the Field of view (FOV) or to improve the apparent resolution of the VR scene. This work will discuss different forms to treat design problems with free-forms, ranging from the direct calculation of point-clouds using the so-called SMS method (followed by a NURBS representation of results) to the combination of direct calculation + optimization. In the latter approach, different types of polynomial descriptions of the free-form surfaces will be considered, with special emphasis on the importance of using a basis that is orthogonal, either with a sag metric or a gradient one.
One of the most interesting problems in the illumination research community is the design of optics able to generate prescribed intensity patterns with extended input sources. Such optics would be ideally applied to the current generation of extended, high-brightness, high-CRI LEDs used in general illumination, allowing reduced size of luminaires and improved efficiency. But in 3D, for non-symmetric configurations, how to design optics for prescribed intensity using extended sources remains an open question. We present an alternative approach to this problem, for the case of extended Lambertian sources, in which the design strategy is based on the definition of selected “edge wavefronts” of an illumination system. The extended emitter is represented by input wavefronts originating from selected points belonging to its edge; the prescribed intensity pattern, instead, is put in relationship with specific output edge wavefronts. The optic is calculated by requiring that it transforms the input edge wavefronts exactly into the output ones. This wavefront-matching procedure can be achieved, for example, with the Simultaneous Multiple Surfaces method (SMS). We show examples of freeform optics calculated according to the above procedure, which create non-rotationally symmetric irradiance patterns out of extended sources. A fine tuning of the output design wavefronts allows accurate control over the uniformity and extension of the output patterns, as well as on the definition of cut-offs and intensity gradients.
We present an advanced optical design for a high-resolution ultra-compact VR headset for high-end applications based on multichannel freeform optics and 4 OLED WUXGA microdisplays developed under EU project LOMID [1]. Conventional optical systems in VR headsets require large distance between lenses and displays that directly leads to the rather bulky and heavy commercial headsets we have at present. We managed to dramatically decrease the required display size itself and the display to eye distance, making it only 36 mm (to be compared to 60-75 mm in most conventional headsets). This ultra-compact optics allows reducing the headset weight and it occupies about a fourth of volume of a conventional headset with the same FOV. Additionally, our multichannel freeform optics provides an excellent image quality and a large field of view (FOV) leading to highly immersive experience. Unlike conventional microlens arrays, which are also multichannel devices, our design uses freeform optical surfaces to produce, even operating in oblique incidences, the highest optical resolution and Nyquist frequency of the VR pixels where it is needed. The LOMID microdisplays used in our headsets are large-area high-resolution (WUXGA) microdisplays with compact, high bandwidth circuitry, including special measures for high contrast by excellent blacks and low-power consumption. LOMID microdisplay diagonal is 0.98” with 16:10 aspect ratio. With two WUXGA microdisplays per eye, our headset has a total of 4,800x1,920 pixels, i.e. close to 5k. As a result, our multichannel freeform optics provides a VR resolution 24 pixels/deg and a monocular FOV of 92x75 degs (or 100x75 with a binocular superposition of 85%).
In present commercial Virtual Reality (VR) headsets the resolution perceived is still limited, since the VR pixel density (typically 10-15 pixels/deg) is well below what the human eye can resolve (60 pixels/deg). We present here novel advanced optical design approaches that dramatically increase the perceived resolution of the VR keeping the large FoV required in VR applications. This approach can be applied to a vast number of optical architectures, including some advanced configurations, as multichannel designs. All this is done at the optical design stage, and no eye tracker is needed in the headset.
We present novel advanced optical designs with a dramatically smaller display to eye distance, excellent image quality and a large field of view (FOV). This enables headsets to be much more compact, typically occupying about a fourth of the volume of a conventional headset with the same FOV. The design strategy of these optics is based on a multichannel approach, which reduces the distance from the eye to the display and the display size itself. Unlike conventional microlens arrays, which are also multichannel devices, our designs use freeform optical surfaces to produce excellent imaging quality in the entire field of view, even when operating at very oblique incidences. We present two families of compact solutions that use different types of lenslets: (1) refractive designs, whose lenslets are composed typically of two refractive surfaces each; and (2) light-folding designs that use prism-like three-surface lenslets, in which rays undergo refraction, reflection, total internal reflection and refraction again. The number of lenslets is not fixed, so different configurations may arise, adaptable for flat or curved displays with different aspect ratios. In the refractive designs the distance between the optics and the display decreases with the number of lenslets, allowing for displaying a light-field when the lenslet becomes significantly small than the eye pupil. On the other hand, the correlation between number of lenslets and the optics to display distance is broken in light-folding designs, since their geometry permits achieving a very short display to eye distance with even a small number of lenslets.
The Freeform RXI collimator is a remarkable example of advanced nonimaging device designed with the 3D Simultaneous Multiple Surface (SMS) Method. In the original design, two (the front refracting surface and the back mirror) of the three optical surfaces of the RXI are calculated simultaneously and one (the cavity surrounding the source) is fixed by the designer. As a result, the RXI perfectly couples two input wavefronts (coming from the edges of the extended LED source) with two output wavefronts (defining the output beam). This allows for LED lamps able to produce controlled intensity distributions, which can and have been successfully applied to demanding applications like high- and low-beams for Automotive Lighting.
Nevertheless, current trends in this field are moving towards smaller headlamps with more shape constraints driven by car design. We present an improved version of the 3D RXI in which also the cavity surface is computed during the design, so that there are three freeform surfaces calculated simultaneously and an additional degree of freedom for controlling the light emission: now the RXI can perfectly couple three input wavefronts with three output wavefronts. The enhanced control over ray beams allows for improved light homogeneity and better pattern definition.
In this work, an optical design approach is presented to design an ultrashort throw distance projection system by combination of an off-the-shelf refractive lens and two off-axis freeform mirrors. These two freeform mirrors are used to greatly shorten the projection distance by more than three times compared to conventional (rotationally symmetric) systems, while still maintaining a good imaging quality. Firstly, a direct design method that enables the simultaneous calculation of two off-axis freeform-profile mirrors by partially coupling more than three fields is introduced. The specifications of the conventional refractive lens are taken into account during this procedure. The pupil matching principle is applied to ensure good performance between the two sub-systems. The calculated mirrors then serve as a good starting point for optimization using commercial optical design software. To step from freeform profiles to freeform surfaces, the calculated two profiles are fitted into odd polynomials to evaluate the image quality and then re-fitted into XY polynomials for further optimization. Finally, the polynomial coefficients of the two freeform mirrors are imported into the optical design program. The merit function is built from RMS spot radii over the full field, and additional constraints are made for correcting distortion. After optimization, the calculated initial design quickly converges to a well performing imaging system. As an example, an ultrashort throw distance projection lens with a large 80-inch diagonal image at 400mm throw distance is designed, analyzed and compared with literature data. The values of MTF are over 0.6 at 0.5 lp/mm and the distortion is less than 1.5%: showing a very good and well balanced imaging performance over the entire field of view.
There is currently a desire to produce thinner LED backlights and frontlights so that the devices which use these components can be as thin and lightweight as possible. This is particularly true for smartphones and tablets both of which make extensive use of such components. The push for thinner devices may lead to situations in which the backlights are thinner than the height of the LED emitting area. This paper deals with the coupling of LEDs and thin light guides, describing some possible ways to efficiently inject light from a relatively large LED into a thinner backlight. These solutions use étendue-squeezing optics, and linear edges which allow high-efficiency light injection.
Today’s SSL illumination market shows a clear trend towards high flux packages with higher efficiency and higher CRI,
realized by means of multiple color chips and phosphors. Such light sources require the optics to provide both near- and
far-field color mixing. This design problem is particularly challenging for collimated luminaries, since traditional
diffusers cannot be employed without enlarging the exit aperture and reducing brightness (so increasing étendue).
Furthermore, diffusers compromise the light output ratio (efficiency) of the lamps to which they are applied.
A solution, based on Köhler integration, consisting of a spherical cap comprising spherical microlenses on both its
interior and exterior sides was presented in 2012. When placed on top of an inhomogeneous multichip Lambertian LED,
this so-called Shell-Mixer creates a homogeneous (both spatially and angularly) virtual source, also Lambertian, where
the images of the chips merge. The virtual source is located at the same position with essentially the same size of the
original source. The diameter of this optics was 3 times that of the chip-array footprint.
In this work, we present a new version of the Shell-Mixer, based on the Edge Ray Principle, where neither the overall
shape of the cap nor the surfaces of the lenses are constrained to spheres or rotational Cartesian ovals. This new Shell-
Mixer is freeform, only twice as large as the original chip-array and equals the original model in terms of brightness,
color uniformity and efficiency.
Today’s SSL illumination market shows a clear trend to high flux packages with higher efficiency and higher CRI, realized by means of multiple color chips and phosphors. Such light sources require the optics to provide both near- and far-field color mixing. This design problem is particularly challenging for collimated luminaries, since traditional diffusers cannot be employed without enlarging the exit aperture and reducing brightness. Furthermore, diffusers compromise the light output ratio (efficiency) of the lamps to which they are applied. A solution, based on Köhler integration, consisting of a spherical cap comprising spherical microlenses on both its interior and exterior sides was presented in 2012. The diameter of this so-called Shell-Mixer was 3 times that of the chip array footprint. A new version of the Shell-Mixer, based on the Edge Ray Principle and conservation of etendue, where neither the outer shape of the cap nor the surfaces of the lenses are constrained to spheres or 2D Cartesian ovals will be shown in this work. The new shell is freeform, only twice as large as the original chip-array and equals the original model in terms of color uniformity, brightness and efficiency.
Transmission-type concentrator photovoltaic (CPV) systems are a potential candidate to achieve high efficiency and low cost solar energy. The use of optical elements in these systems creates reflection losses of incoming solar energy that account for about 8% to 12% depending on the optical design. In order to reduce these losses, we have nanostructured the air/optical-elements’ interfaces by using plasma etching methods on the Fresnel lens made of poly(methyl methacrylate) (PMMA) and the homogenizer made of glass. On flat PMMA and glass substrates, transmittance enhancement measurements are in agreement with relative Jsc gains. The field test results using a CPV module with all textured optical-elements’ interfaces achieved 8.0% and 4.3% relative Jsc and efficiency gains, respectively, demonstrating the potential of this approach to tackle the reflection losses.
KEYWORDS: Solar concentrators, Solar cells, Photovoltaics, Prototyping, Fresnel lenses, Homogenization, Solar energy, Optics manufacturing, Temperature metrology, Concentrated solar cells
The outdoor measurements of a single-cell concentrator PV module reaching a regressed 35.6% efficiency and a maximum peak efficiency of 36.0% (both corrected @Tcell=25ºC) are presented. This is the result of the joint effort by LPI and Solar Junction to demonstrate the potential of combining their respective state-of-the-art concentrator optics and solar cells. The LPI concentrator used is an FK, which is an advanced nonimaging concentrator using 4-channel Köhler homogenization, with a primary Fresnel lens and a refractive secondary made of glass. Solar Junction’s cell is a triplejunction solar cell with the A-SLAMTM architecture using dilute-nitrides.
High flux and high CRI may be achieved by combining different chips and/or phosphors. This, however, results in
inhomogeneous sources that, when combined with collimating optics, typically produce patterns with undesired artifacts.
These may be a combination of spatial, angular or color non-uniformities. In order to avoid these effects, there is a need
to mix the light source, both spatially and angularly. Diffusers can achieve this effect, but they also increase the etendue
(and reduce the brightness) of the resulting source, leading to optical systems of increased size and wider emission
angles.
The shell mixer is an optic comprised of many lenses on a shell covering the source. These lenses perform Kohler
integration to mix the emitted light, both spatially and angularly. Placing it on top of a multi-chip Lambertian light
source, the result is a highly homogeneous virtual source (i.e, spatially and angularly mixed), also Lambertian, which is
located in the same position with essentially the same size (so the average brightness is not increased). This virtual light
source can then be collimated using another optic, resulting in a homogeneous pattern without color separation.
Experimental measurements have shown optical efficiency of the shell of 94%, and highly homogeneous angular
intensity distribution of collimated beams, in good agreement with the ray-tracing simulations.
Two quasi-aplanatic free-form solid V-groove collimators are presented in this work. Both optical designs are originally
designed using the Simultaneous Multiple Surface method in three dimensions (SMS 3D). The second optically active
surface in both free-form V-groove devices is designed a posteriori as a grooved surface. First two mirror (XX) design is
designed in order to clearly show the design procedure and working principle of these devices. Second, RXI free-form
design is comparable with existing RXI collimators; it is a compact and highly efficient design made of polycarbonate
(PC) performing very good colour mixing of the RGGB LED sources placed off-axis. There have been presented
rotationally symmetric non-aplanatic high efficiency collimators with colour mixing property to be improved and
rotationally symmetric aplanatic devices with good colour mixing property and efficiency to be improved. The aim of
this work was to design a free-form device in order to improve colour mixing property of the rotationally symmetric non-aplanatic
RXI devices and the efficiency of the aplanatic ones.
KEYWORDS: Solar concentrators, Prototyping, Electrical efficiency, Solar cells, Solar energy, Dispersion, Fresnel lenses, Temperature metrology, Sun, Optics manufacturing
Most cost-effective concentrated photovoltaics (CPV) systems are based on an optical train comprising two stages, the first being a Fresnel lens. Among them, the Fresnel-Köhler (FK) concentrator stands out owing to both performance and practical reasons. We describe the experimental measurements procedure for FK concentrator modules. This procedure includes three main types of measurements: electrical efficiency, acceptance angle, and irradiance uniformity at the solar cell plane. We have collected here the performance features of two different FK prototypes (ranging different f -numbers, concentration ratios, and cell sizes). The electrical efficiencies measured in both prototypes are high and fit well with the models, achieving values up to 32.7% (temperature corrected, and with no antireflective coating on SOE or POE surfaces) in the best case. The measured angular transmission curves show large acceptance angles, again perfectly matching the expected values [measured concentration acceptance product (CAP) values over 0.56]. The irradiance pattern on the cell (obtained with a digital camera) shows an almost perfectly uniform distribution, as predicted by raytrace simulations. All these excellent on-sun results confirm the FK concentrator as a potentially cost-effective solution for the CPV market.
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.
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). This paper will show the main design features, along with realistic performance simulations considering all spectral characteristics of the elements involved.
Development of a novel HCPV nonimaging concentrator with high concentration (>500x) and built-in spectrum splitting
concept is presented. It uses the combination of a commercial concentration GaInP/GaInAs/Ge 3J cell and a
concentration Back-Point-Contact (BPC) silicon cell for efficient spectral utilization, and external confinement
techniques for recovering the 3J cell's reflection. The primary optical element (POE) is a flat Fresnel lens and the
secondary optical element (SOE) is a free-form RXI-type concentrator with a band-pass filter embedded in it - Both the
POE and SOE performing Köhler integration to produce light homogenization on the receiver. The band-pass filter
transmits the IR photons in the 900-1200 nm band to the silicon cell. A design target of an "equivalent" cell efficiency
~46% is predicted using commercial 39% 3J and 26% Si cells. A projected CPV module efficiency of greater than 38%
is achievable at a concentration level larger than 500X with a wide acceptance angle of ±1°. A first proof-of concept
receiver prototype has been manufactured using a simpler optical architecture (with a lower concentration, ~100x and
lower simulated added efficiency), and experimental measurements have shown up to 39.8% 4J receiver efficiency using
a 3J cell with a peak efficiency of 36.9%.
Here we present a novel optical design of the high concentration photovoltaics (HPCV) nonimaging concentrator
(>500x) with built-in spectrum splitting concept. The primary optical element (POE) is a flat Fresnel lens and the
secondary optical element (SOE) is a free-form RXI-type concentrator with a band-pass filter embedded in it, both POE
and SOE performing Köhler integration to produce light homogenization on the target. It uses the combination of a
commercial concentration GaInP/GaInAs/Ge 3J cell and a concentration Back-Point-Contact (BPC) silicon cell for
efficient spectral utilization, and external confinement techniques for recovering the 3J cell's reflection. Design targets
equivalent cell efficiency ~46% using commercial 39% 3J and 26% Si cells, and CPV module efficiency greater than
38%, achieved at a concentration level larger than 500X and wide acceptance angle (±1°). A first proof-of concept
receiver prototype has been manufactured using a simpler optical architecture (with a lower concentration, ~100x and
lower simulated added efficiency), and experimental measurements have shown up to 39.8% 4J receiver efficiency using
a 3J with peak efficiency of 36.9%.
Concentration Photovoltaics (CPV) is one of the most promising areas for competitive solar electricity production. This
promise relies upon the use of high-efficiency triple-junction solar cells (which already have proven efficiencies over
41%) and upon advanced optics designs, which allow for high concentration concurrent with high manufacturing
tolerances, both key elements for low cost mass production.
In this paper we will present the progress in the development of the most advanced CPV optical designs at present. These
are based on free-form optics using Köhler homogenization. The degree of freedom of using free-forms allows the
introduction of multiple functionalities in a few optical elements, which provide the required concentration with high
tolerance and excellent light homogenization.
Different families are presented. The first group uses a Fresnel lens as a primary optic (called the FK concentrator and
the F-RXI concentrator) and a second group using mirrors as primaries (the XR and the XXR). How they compare
among them and also with classical designs will be discussed. The FK is in the process of being brought to market and
has already experimentally proven module electrical (DC) efficiencies over 30% (equivalent to over 32% with correction
to Tcell=25ºC) with no AR coatings at a concentration of 625x with high tolerance angle (over ±1.2º).
The XR-Köhler concentrator1 is a design that has the possibility to work under high concentration, maintaining the high
acceptance angle and high irradiance uniformity on the solar cell. It is an on-axis free-form design that consists of a
reflective (X) and refractive (R) surface. For a geometrical concentration of about 800x the simulated results show an
acceptance angle of ±1.79deg with high irradiance uniformity on the solar cell. This article shows the design results of
the XR-Köhler and also a novel passive cooling system (LPI patented) that keeps the solar cell operation temperature
under 100°C at extreme conditions (wind speed = 0 m/s, module tilt angle = 45deg and Ta = 50°C). The results of using
the XR-Köhler device as a collimator when the light source has very high non-uniform luminance distribution, i.e.
multichip LEDs, are also here presented.
At module level (one single solar cell), the Fresnel-Köhler (FK) concentrator comprises a perfect irradiance uniformity
along with quite high concentration-acceptance angle product. At the same time, it maintains the efficiency/simplicity of
other Fresnel-based concentrators. In this work we will show the FK concentrator has loose manufacturing tolerances as
well. All these facts, along with the pill-box shape of its transmission curve, permit an enhanced performance of this
device, compared to its competitors, at array level, because the system is more insensitive to manufacturing errors, and
current mismatch is less likely to occur. Or the same performance can be achieved at a lower cost, exhausting the
tolerance budget by using inexpensive fabrication techniques. Depending on the concentrator, the actual power delivered
by an array might drop significantly with respect to the sum of the power delivered by single modules. Under certain
circumstances, the FK can reach a 1-10% electrical efficiency increase with regards to other concentrators sharing the
same technology.
It is essential to obtain high values of tolerance for CPV concentrators because manufacturing process always implies
some accuracy errors. This paper presents the Fresnel Köhler concentrator (FK), an advanced optical concentrator
comprising a Fresnel lens as a primary element and a refractive secondary element, both presenting free-form surfaces.
This optic produces both, the desired light concentration and high tolerance (i.e. high acceptance angle), as well as an
excellent light homogenization by Köhler integration simultaneously. A comparison between the FK and other current
conventional Fresnel-based CPV concentrators is also presented, being our concentrator superior to its competitors in
terms of tolerances, irradiance homogeneity and manufacturability.
The Köhler illumination concept was originally invented to achieve uniform illumination in microscopy1. Köhler
integrators can also be formed by arrays of lenticulations that can be any combination of reflective and/or refractive
surfaces, organized in corresponding pairs. Arrays of integrating facets can be arranged not only on flat surfaces but on
rotationally symmetric and even freeform surfaces6. Currently flat lenslet arrays are widely applied as homogenizing
optics2 for lithography, machine vision illumination, and projection.
Adding Köhler facets onto already designed surfaces can improve the optical system performance, while respecting its
original function. In general, the optics output can be made somewhat independent of the source characteristics, although
at the expense of a slight ètendue dilution or efficiency losses.
This work revises the Köhler concept and its application to different kind of optics, ranging from photovoltaic
concentrators to automotive LED headlights. In the former, irradiance peaks on the solar cell can be avoided, while
preserving high aiming tolerance (acceptance) of the solar concentrator. In the latter, LEDs drawbacks like large source
image sizes, source misalignments, ill defined source edges, and low source radiance can be compensated.
The performance of the XR solar concentrator, using a high efficiency multi-junction solar cell developed
recently by Spectrolab, is presented. The XR concentrator is an ultra-compact Nonimaging optical design
composed of a primary mirror and a secondary lens, which can perform close to the thermodynamic limit
of concentration (maximum acceptance angle for a given geometrical concentration). The expected
acceptance angle of the concentrator is about ±2 deg for a geometrical concentration of 800x (a Fresnel
lens and secondary system typically has ±0.6 deg of acceptance for 300x of geometrical concentration).
This concentrator is optimized to improve the irradiance distribution on the solar cell keeping it under the
maximum values the cell can accept.
The XR concentrator has high manufacturing tolerance to errors and can be produced using low cost
manufacturing techniques. The XR is designed with the Simultaneous Multiple Surface (SMS) design
method of Nonimaging Optics. Its application to high-concentration photovoltaics is now being
developed in a consortium led by The Boeing Company, which has recently been awarded a project by
the US DOE in the framework of the Solar America Initiative.
The performance of the XR solar concentrator, using a high efficiency multi-junction solar cell developed
recently by Spectrolab, is presented. The XR concentrator is an ultra-compact Nonimaging optical design
composed of a primary mirror and a secondary lens, which can perform close to the thermodynamic limit
of concentration (maximum acceptance angle for a given geometrical concentration). The expected
acceptance angle of the concentrator is about ±2 deg for a geometrical concentration of 800x (a Fresnel
lens and secondary system typically has ±0.6 deg of acceptance for 300x of geometrical concentration).
This concentrator is optimized to improve the irradiance distribution on the solar cell keeping it under the
maximum values the cell can accept.
The XR concentrator has high manufacturing tolerance to errors and can be produced using low cost
manufacturing techniques. The XR is designed with the Simultaneous Multiple Surface (SMS) design
method of Nonimaging Optics. Its application to high-concentration photovoltaics is now being
developed in a consortium led by The Boeing Company, which has recently been awarded a project by
the US DOE in the framework of the Solar America Initiative.
A novel LED light extraction and mixing optic and two free form SMS surfaces are employed in a high efficiency projection optic. By combining the light of several high brightness LEDs with a single optical element, an ultrabright light source can be formed, whose shape and emission characteristics can be adapted to almost many kinds of illumination problems. A LED combiner forms a virtual source that is tailored for application. The illuminance distribution of this virtual source facilitates the generation of the desired intensity pattern by projecting it into the far field. The projection is accomplished by one refractive and one reflective freeform surface calculated by the 3D SMS method. The method is demonstrated for an LED automotive headlamp. A high quality intensity pattern shape and a very sharp cutoff are created tolerant to LED to optics misalignment and illuminance variations across the LED surface. A low and high beam design with more than 75% total optical efficiency have been achieved.
KEYWORDS: Solar concentrators, Prisms, Optics manufacturing, Silicon solar cells, Silicon, Manufacturing, Solar cells, Lamps, Design for manufacturability, Photovoltaics
A novel photovoltaic concentrator has been developed in the framework of the European project "High efficiency silicon solar cells concentrator". In this project, front-contacted silicon solar cell have also been designed and manufactured by the project leader (the French LETI). This silicon cell concept is potentially capable to perform well (24% efficiency has been predicted) for much higher concentration levels than the back-contacted cells (and, of course, than the two-side contacted cells).
The concentrator is formed by one lens of squared contour with flat entry surface and large-facet Fresnel exit surface, and a secondary that encapsulates the solar cell. On the contrary to the conventional Fresnel lens plus nonimaging secondary concentrators, the primary and secondary are designed simultaneously, leading to better concentration-acceptance angle product without compromise with the compactness.
The grid lines in the front-contacted cells are aluminium prisms (which contact the p+ and n+ emitters, alternatively), acting as a linear cone concentrator that concentrates Cg =1.52× in the cross sectional dimension of the prisms. The secondary concentrator has a refractive rotational symmetric top surface that is crossed with two linear flow-line TIR mirror. Then, in the cross section normal to the aluminium prisms, the secondary provides a 2D concentration of Cg =12×, while in the cross section parallel to the prisms it provides a 2D concentration of Cg =24.16× as the grid lines in this dimension. Therefore, the cell is rectangular (1:2.08 aspect ratio), being the grid lines parallel to the shorter rectangle side. The total 3D geometrical concentration is 24.16×(12×1.52) = 455× for the square aperture and rectangular cell, and gets a design acceptance angle α=±1.8 degrees.
Injection moulded prototypes are have been manufactured and measured, proving an optical efficiency of 79%. Computer modelling of the concentrator performance will also be presented.
A new design method of free-form Kohler integrator array optics is presented. Only few solutions to the integrator design problem are known, which apply for specific and simple source and targets (for instance, flat integrator lenslet arrays when the source and target are squares located at infinity). The method presented here find more general solutions and the resulting optics is formed by two arrays of free-form optical surfaces (which can be either reflective of refractive). The contour curves of the array units are also obtained from the design.
Two types of Kholer integrators will be defined, depending if they integrate only along one direction across the source (one-directional integrators) or in the two directions (two-directional integrators).
This design method has been applied for an ultra-compact high efficiency LED low beam head lamp producing a legal pattern independently of the chip luminance variation and permitting LED position tolerances of ±200 microns. The ray tracing proves that the high gradient (0.32) and its vertical position in the pattern remain invariable when chip is moved.
The Simultaneous Multiple Surfaces design method (SMS), proprietary technology of Light Prescription Innovators (LPI), was developed in the early 1990's as a two dimensional method. The first embodiments had either linear or rotational symmetry and found applications in photovoltaic concentrators, illumination optics and optical communications. SMS designed devices perform close to the thermodynamic limit and are compact and simple; features that are especially beneficial in applications with today's high brightness LEDs. The method was extended to 3D "free form" geometries in 1999 that perfectly couple two incoming with two outgoing wavefronts. SMS 3D controls the light emitted by an extended light source much better than single free form surface designs, while reaching very high efficiencies. This has enabled the SMS method to be applied to automotive head lamps, one of the toughest lighting tasks in any application, where high efficiency and small size are required. This article will briefly review the characteristics of both the 2D and 3D methods and will present novel optical solutions that have been developed and manufactured to meet real world problems. These include various ultra compact LED collimators, solar concentrators and highly efficient LED low and high beam headlamp designs.
The simultaneous multiple surface (SMS) method in 3-D geometry is presented. Given two orthotomic input ray bundles and another two orthotomic output ray bundles, the method provides an optical system with two free-form surfaces that deflects the rays of the input bundles into the rays of the corresponding output bundles and vice versa. In nonimaging applications, the method enables controlling the light emitted by an extended light source much better than single free-form-surface designs, and also enables the optics contour to be shaped without efficiency losses. The method is also expected to find applications in imaging optics.
The Simultaneous Multiple Surface (SMS) method in 3D geometry is presented. Giving two orthotomic input ray bundles and other two orthotomic output ray bundles, the method provides an optical system with two free-form surfaces that deflects the rays of the input bundles into the rays of the corresponding output bundles and vice versa. In nonimaging applications, the method allows controlling the light emitted by an extended light source much better than single free-form surfaces designs, and also enables the optics contour to be shaped without efficiency losses. The method is expected to find also applications in imaging optics
In this work we present laser-based novel devices that maximize the emitted power for constant eye safety level and beam divergence angle, i.e., without affecting the eye safety classification or the necessary tracking accuracy. This is achieved by breaking the spatial coherence of the beam, which allows the system to be considered as an extended light source. The system comprises a laser, a diffuser, a collimator and, sometimes, other optical elements. As an example, one of the devices is composed of a laser, a Lambertian reflective-type diffuser, and a single-piece reflective-refractive collimator of 20 mm aperture and ultra-high numerical aperture (NA = 1.43), which re-collimates the radiation into 3.5 deg. (full angle). According to the IEC 60825-1:1993 (amendment 2, 2001-01), the Accessible Emission Limit (AEL) (Class 1, wavelength λ = 780 nm, exposure T = 30000 s) for this device is 35.9 times greater than that of a laser with the same divergence angle (15.6 dB), i.e., this device is allowed to emit 35.9 times more power than that of the laser alone with the same divergence angle. The switching time, the beam divergence and the eye safety classification remain the same. This power gain varies with the design conditions. In the cases analyzed it goes from = 8.4 (9.24dB) to 551.3 (27.4 dB).
The 30 X DSMTS is a trough-like photovoltaic concentrator, meant to track the sun in one axis, which has a mirror allocating two concentration stages and a secondary lens that increases its acceptance up to +/- 2.3 degrees. Provided that the sun subtends an angle of +/- 0.256 degrees, such acceptance seems excessive. However, thanks to it, we can relax requirements that often demand accuracy in systems of the kind. For instance, the shape of the mirror can be achieved by simply bending an aluminum sheet. To foresee the results we may expect of this strategy, we carried out some mechanical calculations, whose results are the boundary conditions that lead to a minimum standard deviation on the local slope of the elastic mirror with regards to the theoretical value. We checked by ray tracing that such an error actually provoked a small decrease on the acceptance. This fact persuaded us to carry out the manufacture of two elastic prototypes. In the test that have been performed so far with them we achieved an acceptance angle of +/- 1.63 degrees and a collection efficiency of 98 percent at a geometrical concentration of 30 times, results that can be considered as outstanding in the photovoltaics framework.
Advanced optical design methods using the keys of nonimaging optics lead to some ultra compact designs which combine the concentrating (or collimating) capabilities of conventional long focal length systems with a high collection efficiency. One of those designs is the so-called RXI. Its aspect ratio (thickness/aperture diameter) is less than 1/3. Used as a receiver, i.e. placing a photodiode at the proper position, it gets an irradiance concentration of the 95% of the theoretical thermodynamic limit (this means for example, a concentration of 1600 times with an acceptance angle of +/- 2.14 degrees). When used as an emitter (replacing the aforementioned photodiode by an LED, for instance), similar intensity gains may be obtained within an angle cone almost as wide as the 95% of the thermodynamic limit. In a real device these irradiance(and intensity)gains are reduced by the optical efficiency. This combination of high concentration factors, relatively wide angles, simplicity and compactness make the optical device almost unique. This work will show the results of the measurements done with several RXI prototypes of 40-mm aperture diameter, all of them made of PMMA (by injection process).
In this work the variational calculus will be applied to the design with axisymmetric sequential optical surfaces for small sources directly in 3D. This method is proven to be useful even in the case in which the skewness distributions of output bundle and emitter do not fit. The tool provides both the optimum 3D ray bundles at the exit aperture of a rotational collimator and the best 2D assignation of rays allowing the collimation reach its limit. Once this best assignation has been obtained, the optical profiles can be designed easily using only the central ray of the bundles. Afterwards, the actual device is obtained by rotation. As a consequence of the kind of method aforementioned, the angular performance of the collimators can be nearly error- free predicted before ray tracing.
Two new static nonimaging designs for bifacial solar cells are presented. These concentrators have been obtained with the Simultaneous Multiple Surface design method of Nonimaging Optics. The main characteristics of these concentrators are: (1) high compactness, (2) linear symmetry (in order to be made by low cost extrusion), (3) performance close to the thermodynamic limit, and (4) a non-shading sizable gap between at least one of the cell edges and the optically active surfaces. This last feature is interesting because this gap can be used to allocate the interconnections between cells, with no additional optical losses. As an example of the results, one design for an acceptable angle of +/- 30 degrees gets a geometrical concentration of 5.5X, with an average thickness to entry aperture width ratio of 0.24. The 3D ray-tracing analysis of the concentrators is also presented.
The Simultaneous Multiple Surfaces of Nonimaging Optics has been used successfully in the past for the synthesis of concentrators in two dimensions. In this paper we present a first approach to extend this design method to 3D geometry. As a first result, an aspheric lens without rotational symmetry that focus sharply two plane wavefronts at two points in 3D geometry is found, feature which cannot be obtained with an axisymmetric optical system with a finite number of optical surfaces.
The design of non-sequential mirrors within the Simultaneous Multiple Surface design method of nonimaging concentrators is presented. The formulation of the edge ray theorem for this problem is stated, which defines the rays to be considered in the design. As a result three new nonimaging concentrators are developed, which work efficiently and close to the thermodynamic limit of concentration in two dimensions.
A 2D-error model for nonimaging concentrators composed by multiple optical surfaces is presented. The concentrator surfaces can be either dioptrics, sequential mirrors (as a conventional parabola) or non-sequential mirrors (i.e. CPC- like mirrors). Under the hypothesis of the model, the slope errors of all the surfaces can be transferred to entry aperture and combined there, and the effect of errors can be studied with a single probability density function as in the case of one-mirror concentrators. A single number, the concentrator error multiplier, is defined to characterize the concentrator tolerance to errors. This number and the concentrator acceptance angle are the key to analyze the error sensitivity of concentrators. Finally the model is used to quantify the maximum tolerance on the concentrators surfaces to guarantee a specified quality.
Two new types of two-mirror solar concentrator for tubular receiver, the snail concentrator and the helmet concentrator , are presented. The main feature of these concentrators is that they have a sizable gap between the secondary mirror and the absorber, and they still achieve concentrations close to the thermodynamic limit with high collection efficiencies. This characteristic makes them unique and, on the contrary to the present two-stage designs, allows for the location of the secondary outside the evacuated tube. One of the differences between the snail and the helmet concentrators is that the last is symmetric (as the conventional parabolic trough) but the first is not. For an acceptance angle of (alpha) equals +/- 0.73 degs and a collection efficiency of 96.8% (i.e. 3.2% of the rays incident on the primary mirror within the acceptance angle are rejected), the snail concentrator and the helmet concentrator achieve an average flux concentration of 91.1% and 72.8% of the thermodynamic limit, respectively. The gap between the absorber and the secondary mirror is 6.8 and 12.1 times the absorber radius for each concentrator. Moreover, both concentrators have also high rim angles of the primary mirror: +/- 86.2 degs (helmet) and 3.1 - 98.8 degs (snail). This is of interest for a good mechanical stability of the collector.
Access to the requested content is limited to institutions that have purchased or subscribe to SPIE eBooks.
You are receiving this notice because your organization may not have SPIE eBooks access.*
*Shibboleth/Open Athens users─please
sign in
to access your institution's subscriptions.
To obtain this item, you may purchase the complete book in print or electronic format on
SPIE.org.
INSTITUTIONAL Select your institution to access the SPIE Digital Library.
PERSONAL Sign in with your SPIE account to access your personal subscriptions or to use specific features such as save to my library, sign up for alerts, save searches, etc.