Skip to main content
SpringerLink
Log in

Manufacturing of Compound Parabolic Concentrator Devices Using an Ultra-fine Planing Method for Enhancing Efficiency of a Solar Cell

  • Regular Paper
  • Published:
International Journal of Precision Engineering and Manufacturing-Green Technology Aims and scope Submit manuscript

Abstract

Various structural patterns are used to control light properties during propagation. In particular, when light is trapped and concentrated onto solar cells, they generate more electricity than without concentration. Since the sun moves continuously, a compound parabolic concentrator (CPC) can enhance the efficiency of solar cells by light-trapping and concentration because a CPC minimizes optical loss by reducing the reflection and the scattering on the surface of solar cells. However, CPC devices are generally expensive to manufacture and are too large in size to be used for applications requiring portability. Here, we developed a novel manufacturing process for a small CPC device and verified the enhanced efficiency of solar cells. Based on ultra-fine planing and injection molding, this process is an efficient method for mass production because it relies on replication. Two metal molds were precisely machined using an ultra-fine planing method with a diamond tool, and a CPC device was accurately manufactured by injection molding at low cost and within one minute. The variation of the specific cutting resistance during machining of the metal molds increased by four times, and the minimum uncut chip thickness decreased from 1.3 to 0.5 μm, which is called a size effect. The finished CPC device exhibited a surface roughness less than 40 nm and showed high optical efficiency in virtue of light-trapping. Finally, the efficiency of a solar cell with the CPC device was enhanced about 10%.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12

source of a wavelength of a 633 nm

Fig. 13
Fig. 14

Similar content being viewed by others

References

  1. Zhu, W. L., Duan, F., Zhang, X., Zhu, Z., & Ju, B. F. (2018). A new diamond machining approach for extendable fabrication of micro-freeform lens array. International Journal of Machine Tools and Manufacturing, 125, 134–148.

    Article  Google Scholar 

  2. Zhu, Z., To, S., & Zhang, S. (2015). Theoretical and experimental investigation on the novel end-fly-cutting-servo diamond machining of hierarchical micro-nanostructures. International Journal of Machine Tools and Manufacturing, 94, 15–25.

    Article  Google Scholar 

  3. Karp, J. H., Tremblay, E. J., & Ford, J. E. (2010). Planar micro-optic solar concentrator. Optics Express, 18(2), 1122–1133.

    Article  Google Scholar 

  4. Wang, Y., Zhu, Y., Chen, H., Zhang, X., Yang, L., & Liao, C. (2015). Performance analysis of a novel sun-tracking CPC heat pipe evacuated tubular collector. Applied Thermal Engineering, 87, 381–388.

    Article  Google Scholar 

  5. Kosten, E. D., Atwater, J. H., Parsons, J., Polman, A., & Atwater, H. A. (2013). Highly efficient GaAs solar cells by limiting light emission angle. Light Science and Applications. https://doi.org/10.1038/lsa.2013.1.

    Article  Google Scholar 

  6. Rau, U., Paetzold, U. W., & Kirchartz, T. (2014). Thermodynamics of light management in photovoltaic devices. Physical Review B, 90, 035211.

    Article  Google Scholar 

  7. Tvingstedt, K., Zilio, S. D., Inganäs, O., & Termen, M. (2008). Trapping light with micro lenses in thin film organic photovoltaic cells. Optics Express, 16(26), 21608–21615.

    Article  Google Scholar 

  8. Cho, C., Song, J. H., Kim, C., Jeong, S., & Lee, J. Y. (2017). Broadband light trapping strategies for quantum-dot photovoltaic cells (>10%) and their issues with the measurement of photovoltaic characteristics. Scientific Reports. https://doi.org/10.1038/s41598-017-17550-4.

    Article  Google Scholar 

  9. Tian, M., Su, Y., Zheng, H., Pei, G., Li, G., & Riffat, S. (2018). A review on the recent research progress in the compound parabolic concentrator (CPC) for solar energy applications. Renewable and Sustainable Energy Reviews, 82, 1272–1296.

    Article  Google Scholar 

  10. Karathanassis, I. K., Papanicolaou, E., Belessiotis, V., & Gergeles, G. C. (2017). Design and experimental evaluation of a parabolic-trough concentrating photovoltaic/thermal (CPVT) system with high-efficiency cooling. Renewable Energy, 101, 467–483.

    Article  Google Scholar 

  11. Bahaidarah, H. M., Tanweer, B., Gandhidasan, P., Ibrahim, N., & Rehman, S. (2014). Experimental and numerical study on non-concentrating and symmetric unglazed compound parabolic photovoltaic concentration systems. Applied Energy, 136, 527–536.

    Article  Google Scholar 

  12. Li, G., Pei, G., Ji, J., Yang, M., Su, Y., & Xu, N. (2015). Numerical and experimental study on a PV/T system with static miniature solar concentrator. Solar Energy, 120, 565–574.

    Article  Google Scholar 

  13. Senthilkumar, S., & Yasodha, N. (2012). Design and development of a three dimensional compound parabolic concentrator and study of optical and thermal performance. International Journal of Energy Science, 2(2), 64–68.

    Google Scholar 

  14. Abu-Bakar, S. H., Muhammad-Sukki, F., Freier, D., Ramirez-Inguez, R., Mllick, T. K., Munir, A. B., et al. (2015). Performance analysis of a novel rotationally asymmetrical compound parabolic concentrator. Applied Energy, 154, 221–231.

    Article  Google Scholar 

  15. Walze, G., Nitz, P., Ell, J., Georg, A., Gombert, A., & Hossfeld, W. (2005). Combination of microstructures andoptically functional coatings for solar control glazing. Solar energy Materials and Solar cells, 89, 233–248.

    Article  Google Scholar 

  16. Hassan, H. U., Lacraz, A., Kalli, K., & Bang, O. (2017). Femtosecond laser micromachining of compound parabolic concentrator fiber tipped glucose sensors. Journal of Biomedical Optics, 22(3), 037003.

    Article  Google Scholar 

  17. Vu, N. H., & Shin, S. (2016). Cost-effective optical fiber daylighting system using modified compound parabolic concentrators. Solar Energy, 136, 145–152.

    Article  Google Scholar 

  18. Chen, B., Li, S., Deng, Z., Guo, B., & Zhao, Q. (2017). Grinding marks on ultra-precision grinding spherical and aspheric surfaces. International journal of Precision Engineering and Manufacturing-Green Technology, 4(4), 419–429.

    Article  Google Scholar 

  19. Yan, G., You, K., & Fang, F. (2020). Three-Linear-Axis Grinding of Small Aperture Aspheric Surfaces. International journal of Precision Engineering and Manufacturing-Green Technology, 7, 997–1008.

    Article  Google Scholar 

  20. Cho, C., Jeong, S., Choi, H. J., Shin, N., Kim, B. S., Jeon, E. C., & Lee, J. Y. (2015). Toward perfect light trapping in thin-film photovoltaic cells: full utilization of the dual characteristics of light. Advanced Optical Materials, 3, 1697–1702.

    Article  Google Scholar 

  21. Son, S. M., Lim, H. S., & Ahn, J. H. (2005). Effects of the friction coefficient on the minimum cutting thickness in micro cutting. International Journal of Machine Tools and Manufacturing, 45, 529–535.

    Article  Google Scholar 

  22. Lucca, D. A., Rhorer, R. L., & Komanduri, R. (1991). Energy dissipation in the ultraprecision machining of copper. CIRP Annals, 40(1), 69–72.

    Article  Google Scholar 

  23. Liu, K., & Melkote, S. N. (2006). Material strengthening mechanisms and their contribution to size effect in micro-cutting. Journal of Manufacturing Science and Engineering, 128(3), 730–738.

    Article  Google Scholar 

  24. Holthusen, A. K., Riemer, O., Schmutz, J., & Meier, A. (2017). Mold machining and injection molding of diffractive microstructures. Journal of Manufacturing Process, 26, 290–294.

    Article  Google Scholar 

  25. Tanaka, K., Pacheco, M. T. T., Brennan, J. F., III., Itzkan, I., Berger, A. J., Dasari, R. R., & Feld, M. S. (1996). Compound parabolic concentrator probe for efficient light collection in spectroscopy of biological tissue. Applied Opitcs, 35(4), 758–763.

    Article  Google Scholar 

Download references

Acknowledgements

This research was supported by Basic Science Research Program through the National Research Foundation of Korea (NRF) funded by the Ministry of Education (2019R1I1A3A01054545), Creative Material Discovery Program through the National Research Foundation of Korea (NRF) funded by the Ministry of Science and ICT (MSIT) (2020M3D1A2102756) and the Korea Basic Science Institute (KBSI) (Project No. C030224).

Author information

Authors and Affiliations

  1. Center for Research Equipment, Korea Basic Science Institute, Daejeon, 34133, South Korea

    Hwan-Jin Choi, Minwoo Jeon & Geon-Hee Kim

  2. Dresden Integrated Center for Applied Physics and Photonic Materials (IAPP), Technische Universität Dresden, Dresden, 01187, Germany

    Changsoon Cho

  3. School of Electrical Engineering (EE), Korea Advanced Institute of Science and Technology, Daejeon, 34141, South Korea

    Changsoon Cho & Jung-Yong Lee

  4. Department of Nano-Manufacturing Technology, Korea Institute of Machinery and Material, Daejeon, 34103, South Korea

    Sangwon Woo, Yeong-Eun Yoo & Tae-Jin Je

  5. School of Materials Science and Engineering, University of Ulsan, Ulsan, 44610, South Korea

    Eun-chae Jeon

Authors
  1. Hwan-Jin Choi
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Changsoon Cho
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Sangwon Woo
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Jung-Yong Lee
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Yeong-Eun Yoo
    View author publications

    You can also search for this author in PubMed Google Scholar

  6. Minwoo Jeon
    View author publications

    You can also search for this author in PubMed Google Scholar

  7. Geon-Hee Kim
    View author publications

    You can also search for this author in PubMed Google Scholar

  8. Tae-Jin Je
    View author publications

    You can also search for this author in PubMed Google Scholar

  9. Eun-chae Jeon
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding authors

Correspondence to Tae-Jin Je or Eun-chae Jeon.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Choi, HJ., Cho, C., Woo, S. et al. Manufacturing of Compound Parabolic Concentrator Devices Using an Ultra-fine Planing Method for Enhancing Efficiency of a Solar Cell. Int. J. of Precis. Eng. and Manuf.-Green Tech. 8, 1405–1414 (2021). https://doi.org/10.1007/s40684-020-00287-3

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s40684-020-00287-3

Keywords

Search

Navigation