Fabrication of high-performance lens arrays for micro-concentrator photovoltaics using ultraviolet imprinting

Abstract Micro-concentrator photovoltaics (micro-CPV) is a cutting-edge CPV approach aimed at increasing the efficiency and reducing the cost and carbon footprint of solar electricity by downscaling concentrator solar cells and optics. The reduced size of micro-CPV provides several advantages over conventional CPV, including shorter optical paths and lower temperature and resistive losses in the cell, resulting in higher electrical efficiencies. This may increase the energy yield per area compared to conventional CPV or silicon modules. Cost reduction is achieved through material savings and the use of continuous manufacturing methods enabled by the tiny size of cells and optics, such as roll-to-roll (R2R) and roll-to-plate (R2P) ultraviolet (UV) imprinting for optics production. However, adapting these processes to large-area arrays of Fresnel micro-lenses with no wasted areas and high efficiency remains a challenge. In this study, we present a comprehensive methodology for the development of micro-CPV optics with full area coverage—from design and mastering to up-scaling, tooling, and replication. The methodology involves designing a non-rotationally symmetric elementary insert tailored to ultraviolet imprinting. Crucially, multiple inserts are originated via precision machining and recombined to form a single array master mold without wasted areas. The master is then replicated into a flexible working stamp for UV imprinting of Fresnel lens arrays, utilizing different UV curable materials. The functional characterization of the lenses demonstrates an optical efficiency of 80% at 178X under collimated white light, representing the highest effective concentration achieved using UV-imprinted Fresnel lenses. Furthermore, initial reliability tests confirm the absence of degradation during thermal cycling or outdoor exposure. This methodology paves the way for continuous high-throughput manufacturing of micro-lens arrays using R2R or R2P methods, presenting a significant step forward in micro-CPV.