Manufacturing of Compound Parabolic Concentrator Devices Using an Ultra-fine Planing Method for Enhancing Efficiency of
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Manufacturing of Compound Parabolic Concentrator Devices Using an Ultra‑fine Planing Method for Enhancing Efficiency of a Solar Cell Hwan‑Jin Choi1 · Changsoon Cho2,3 · Sangwon Woo4 · Jung‑Yong Lee3 · Yeong‑Eun Yoo4 · Minwoo Jeon1 · Geon‑Hee Kim1 · Tae‑Jin Je4 · Eun‑chae Jeon5 Received: 18 September 2020 / Revised: 28 October 2020 / Accepted: 2 November 2020 © Korean Society for Precision Engineering 2020
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%. Keywords Ultra-fine planing · Compound parabolic concentrator · Surface roughness · Power conversion efficiency · Solar cell
1 Introduction * Tae‑Jin Je [email protected] * Eun‑chae Jeon [email protected] 1
Center for Research Equipment, Korea Basic Science Institute, Daejeon 34133, South Korea
2
Dresden Integrated Center for Applied Physics and Photonic Materials (IAPP), Technische Universität Dresden, Dresden 01187, Germany
3
School of Electrical Engineering (EE), Korea Advanced Institute of Science and Technology, Daejeon 34141, South Korea
4
Department of Nano‑Manufacturing Technology, Korea Institute of Machinery and Material, Daejeon 34103, South Korea
5
School of Materials Science and Engineering, University of Ulsan, Ulsan 44610, South Korea
Various shapes of optical components have been developed to control light propagation characteristics such as concentration, reflection, refraction, diffusion, and so on. Generally, pyramidal, prismatic, and curved shapes are used for refraction/self-reflection, concentration, and diffusion, respe
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