Molding arrays of tertiary optical elements for microcell receivers

Trough-Lens-Cone PV, or TLC, is a CPV module architecture that uses three-stage optics to enable high concentration at low cost. A trough mirror concentrates similar to 40X on one axis onto a long, narrow module. The module cover has linear lenses on front that reconcentrate similar to 10X on a second axis, producing a series of narrow similar to 400X focal lines. The final optical stage is an array of CPC (compound-parabolic-curve) cones that raise the concentration to similar to 1500X. A receiver has an array of microcells in parallel to handle the trough's uneven concentration, and each cone funnels light to a microcell. Suitable parabolic troughs are already low cost, the lenses are designed to be roll-formed at very low cost, and the arrays of microcells can be assembled at low cost. However, forming the arrays of tiny cones is a potential obstacle. This paper describes criteria that the cones should meet, the challenges of producing suitable cones, the proposed cone-molding process, and first results from proof-of-concept prototyping of the proposed process.