Abstract

Roll-to-roll manufacturing has been proven to be a high-throughput and low-cost technology for continuous fabrication of functional optical polymer films. In this paper, we have firstly studied a complete manufacturing cycle of linear Fresnel lens polymer film for solar concentration in the aspects of ultra-precision diamond machining of metal roller mold, roll-to-roll embossing, and measurement on film profile and functionality. A metal roller mold patterned with linear Fresnel lenses is obtained using single point diamond turning technique. The roller mold is installed onto a self-developed roll-to-roll UV embossing system to realize continuous manufacturing of linear Fresnel lens film. Profile measurement of the machined roller mold and the embossed polymer film, which is conducted using a stylus profilometer, shows good agreement between measured facet angles with designed ones. Functionality test is conducted on a solar simulation system with a reference solar cell, and results show that strong light concentration is realized.

© 2014 Optical Society of America

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References

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  1. D. T. Nelson, D. L. Evans, and R. K. Bansal, “Linear Fresnel lens concentrators,” Sol. Energy 17(5), 285–289 (1975).
    [Crossref]
  2. H. Zhai, Y. J. Dai, J. Y. Wu, R. Z. Wang, and L. Y. Zhang, “Experimental investigation and analysis on a concentrating solar collector using linear Fresnel lens,” Energy Convers. Manage. 51(1), 48–55 (2010).
    [Crossref]
  3. Z. W. Zhong and X. C. Shan, “Microstructure formation via roll-to-roll UV embossing using a flexible mould made from a laminated polymer–copper film,” J. Micromech. Microeng. 22(8), 085010 (2012).
    [Crossref]
  4. L. Yeo, S. Ng, Z. Wang, H. Xia, Z. Wang, V. Thang, Z. Zhong, and N. de Rooij, “Investigation of hot roller embossing for microfluidic devices,” J. Micromech. Microeng. 20(1), 015017 (2010).
    [Crossref]
  5. R. C. Allen, L. W. Carlson, A. J. Ouderkirk, M. F. Weber, A. L. Kotz, T. J. Nevitt, C. A. Stover, and B. Majumdar, “Brightness enhancement film,” (2000).
  6. W. T. Xie, Y. J. Dai, R. Z. Wang, and K. Sumathy, “Concentrated solar energy applications using Fresnel lenses: A review,” Renew. Sustain. Energy Rev. 15(6), 2588–2606 (2011).
    [Crossref]

2012 (1)

Z. W. Zhong and X. C. Shan, “Microstructure formation via roll-to-roll UV embossing using a flexible mould made from a laminated polymer–copper film,” J. Micromech. Microeng. 22(8), 085010 (2012).
[Crossref]

2011 (1)

W. T. Xie, Y. J. Dai, R. Z. Wang, and K. Sumathy, “Concentrated solar energy applications using Fresnel lenses: A review,” Renew. Sustain. Energy Rev. 15(6), 2588–2606 (2011).
[Crossref]

2010 (2)

L. Yeo, S. Ng, Z. Wang, H. Xia, Z. Wang, V. Thang, Z. Zhong, and N. de Rooij, “Investigation of hot roller embossing for microfluidic devices,” J. Micromech. Microeng. 20(1), 015017 (2010).
[Crossref]

H. Zhai, Y. J. Dai, J. Y. Wu, R. Z. Wang, and L. Y. Zhang, “Experimental investigation and analysis on a concentrating solar collector using linear Fresnel lens,” Energy Convers. Manage. 51(1), 48–55 (2010).
[Crossref]

1975 (1)

D. T. Nelson, D. L. Evans, and R. K. Bansal, “Linear Fresnel lens concentrators,” Sol. Energy 17(5), 285–289 (1975).
[Crossref]

Allen, R. C.

R. C. Allen, L. W. Carlson, A. J. Ouderkirk, M. F. Weber, A. L. Kotz, T. J. Nevitt, C. A. Stover, and B. Majumdar, “Brightness enhancement film,” (2000).

Bansal, R. K.

D. T. Nelson, D. L. Evans, and R. K. Bansal, “Linear Fresnel lens concentrators,” Sol. Energy 17(5), 285–289 (1975).
[Crossref]

Carlson, L. W.

R. C. Allen, L. W. Carlson, A. J. Ouderkirk, M. F. Weber, A. L. Kotz, T. J. Nevitt, C. A. Stover, and B. Majumdar, “Brightness enhancement film,” (2000).

Dai, Y. J.

W. T. Xie, Y. J. Dai, R. Z. Wang, and K. Sumathy, “Concentrated solar energy applications using Fresnel lenses: A review,” Renew. Sustain. Energy Rev. 15(6), 2588–2606 (2011).
[Crossref]

H. Zhai, Y. J. Dai, J. Y. Wu, R. Z. Wang, and L. Y. Zhang, “Experimental investigation and analysis on a concentrating solar collector using linear Fresnel lens,” Energy Convers. Manage. 51(1), 48–55 (2010).
[Crossref]

de Rooij, N.

L. Yeo, S. Ng, Z. Wang, H. Xia, Z. Wang, V. Thang, Z. Zhong, and N. de Rooij, “Investigation of hot roller embossing for microfluidic devices,” J. Micromech. Microeng. 20(1), 015017 (2010).
[Crossref]

Evans, D. L.

D. T. Nelson, D. L. Evans, and R. K. Bansal, “Linear Fresnel lens concentrators,” Sol. Energy 17(5), 285–289 (1975).
[Crossref]

Kotz, A. L.

R. C. Allen, L. W. Carlson, A. J. Ouderkirk, M. F. Weber, A. L. Kotz, T. J. Nevitt, C. A. Stover, and B. Majumdar, “Brightness enhancement film,” (2000).

Majumdar, B.

R. C. Allen, L. W. Carlson, A. J. Ouderkirk, M. F. Weber, A. L. Kotz, T. J. Nevitt, C. A. Stover, and B. Majumdar, “Brightness enhancement film,” (2000).

Nelson, D. T.

D. T. Nelson, D. L. Evans, and R. K. Bansal, “Linear Fresnel lens concentrators,” Sol. Energy 17(5), 285–289 (1975).
[Crossref]

Nevitt, T. J.

R. C. Allen, L. W. Carlson, A. J. Ouderkirk, M. F. Weber, A. L. Kotz, T. J. Nevitt, C. A. Stover, and B. Majumdar, “Brightness enhancement film,” (2000).

Ng, S.

L. Yeo, S. Ng, Z. Wang, H. Xia, Z. Wang, V. Thang, Z. Zhong, and N. de Rooij, “Investigation of hot roller embossing for microfluidic devices,” J. Micromech. Microeng. 20(1), 015017 (2010).
[Crossref]

Ouderkirk, A. J.

R. C. Allen, L. W. Carlson, A. J. Ouderkirk, M. F. Weber, A. L. Kotz, T. J. Nevitt, C. A. Stover, and B. Majumdar, “Brightness enhancement film,” (2000).

Shan, X. C.

Z. W. Zhong and X. C. Shan, “Microstructure formation via roll-to-roll UV embossing using a flexible mould made from a laminated polymer–copper film,” J. Micromech. Microeng. 22(8), 085010 (2012).
[Crossref]

Stover, C. A.

R. C. Allen, L. W. Carlson, A. J. Ouderkirk, M. F. Weber, A. L. Kotz, T. J. Nevitt, C. A. Stover, and B. Majumdar, “Brightness enhancement film,” (2000).

Sumathy, K.

W. T. Xie, Y. J. Dai, R. Z. Wang, and K. Sumathy, “Concentrated solar energy applications using Fresnel lenses: A review,” Renew. Sustain. Energy Rev. 15(6), 2588–2606 (2011).
[Crossref]

Thang, V.

L. Yeo, S. Ng, Z. Wang, H. Xia, Z. Wang, V. Thang, Z. Zhong, and N. de Rooij, “Investigation of hot roller embossing for microfluidic devices,” J. Micromech. Microeng. 20(1), 015017 (2010).
[Crossref]

Wang, R. Z.

W. T. Xie, Y. J. Dai, R. Z. Wang, and K. Sumathy, “Concentrated solar energy applications using Fresnel lenses: A review,” Renew. Sustain. Energy Rev. 15(6), 2588–2606 (2011).
[Crossref]

H. Zhai, Y. J. Dai, J. Y. Wu, R. Z. Wang, and L. Y. Zhang, “Experimental investigation and analysis on a concentrating solar collector using linear Fresnel lens,” Energy Convers. Manage. 51(1), 48–55 (2010).
[Crossref]

Wang, Z.

L. Yeo, S. Ng, Z. Wang, H. Xia, Z. Wang, V. Thang, Z. Zhong, and N. de Rooij, “Investigation of hot roller embossing for microfluidic devices,” J. Micromech. Microeng. 20(1), 015017 (2010).
[Crossref]

L. Yeo, S. Ng, Z. Wang, H. Xia, Z. Wang, V. Thang, Z. Zhong, and N. de Rooij, “Investigation of hot roller embossing for microfluidic devices,” J. Micromech. Microeng. 20(1), 015017 (2010).
[Crossref]

Weber, M. F.

R. C. Allen, L. W. Carlson, A. J. Ouderkirk, M. F. Weber, A. L. Kotz, T. J. Nevitt, C. A. Stover, and B. Majumdar, “Brightness enhancement film,” (2000).

Wu, J. Y.

H. Zhai, Y. J. Dai, J. Y. Wu, R. Z. Wang, and L. Y. Zhang, “Experimental investigation and analysis on a concentrating solar collector using linear Fresnel lens,” Energy Convers. Manage. 51(1), 48–55 (2010).
[Crossref]

Xia, H.

L. Yeo, S. Ng, Z. Wang, H. Xia, Z. Wang, V. Thang, Z. Zhong, and N. de Rooij, “Investigation of hot roller embossing for microfluidic devices,” J. Micromech. Microeng. 20(1), 015017 (2010).
[Crossref]

Xie, W. T.

W. T. Xie, Y. J. Dai, R. Z. Wang, and K. Sumathy, “Concentrated solar energy applications using Fresnel lenses: A review,” Renew. Sustain. Energy Rev. 15(6), 2588–2606 (2011).
[Crossref]

Yeo, L.

L. Yeo, S. Ng, Z. Wang, H. Xia, Z. Wang, V. Thang, Z. Zhong, and N. de Rooij, “Investigation of hot roller embossing for microfluidic devices,” J. Micromech. Microeng. 20(1), 015017 (2010).
[Crossref]

Zhai, H.

H. Zhai, Y. J. Dai, J. Y. Wu, R. Z. Wang, and L. Y. Zhang, “Experimental investigation and analysis on a concentrating solar collector using linear Fresnel lens,” Energy Convers. Manage. 51(1), 48–55 (2010).
[Crossref]

Zhang, L. Y.

H. Zhai, Y. J. Dai, J. Y. Wu, R. Z. Wang, and L. Y. Zhang, “Experimental investigation and analysis on a concentrating solar collector using linear Fresnel lens,” Energy Convers. Manage. 51(1), 48–55 (2010).
[Crossref]

Zhong, Z.

L. Yeo, S. Ng, Z. Wang, H. Xia, Z. Wang, V. Thang, Z. Zhong, and N. de Rooij, “Investigation of hot roller embossing for microfluidic devices,” J. Micromech. Microeng. 20(1), 015017 (2010).
[Crossref]

Zhong, Z. W.

Z. W. Zhong and X. C. Shan, “Microstructure formation via roll-to-roll UV embossing using a flexible mould made from a laminated polymer–copper film,” J. Micromech. Microeng. 22(8), 085010 (2012).
[Crossref]

Energy Convers. Manage. (1)

H. Zhai, Y. J. Dai, J. Y. Wu, R. Z. Wang, and L. Y. Zhang, “Experimental investigation and analysis on a concentrating solar collector using linear Fresnel lens,” Energy Convers. Manage. 51(1), 48–55 (2010).
[Crossref]

J. Micromech. Microeng. (2)

Z. W. Zhong and X. C. Shan, “Microstructure formation via roll-to-roll UV embossing using a flexible mould made from a laminated polymer–copper film,” J. Micromech. Microeng. 22(8), 085010 (2012).
[Crossref]

L. Yeo, S. Ng, Z. Wang, H. Xia, Z. Wang, V. Thang, Z. Zhong, and N. de Rooij, “Investigation of hot roller embossing for microfluidic devices,” J. Micromech. Microeng. 20(1), 015017 (2010).
[Crossref]

Renew. Sustain. Energy Rev. (1)

W. T. Xie, Y. J. Dai, R. Z. Wang, and K. Sumathy, “Concentrated solar energy applications using Fresnel lenses: A review,” Renew. Sustain. Energy Rev. 15(6), 2588–2606 (2011).
[Crossref]

Sol. Energy (1)

D. T. Nelson, D. L. Evans, and R. K. Bansal, “Linear Fresnel lens concentrators,” Sol. Energy 17(5), 285–289 (1975).
[Crossref]

Other (1)

R. C. Allen, L. W. Carlson, A. J. Ouderkirk, M. F. Weber, A. L. Kotz, T. J. Nevitt, C. A. Stover, and B. Majumdar, “Brightness enhancement film,” (2000).

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Figures (6)

Fig. 1
Fig. 1 Construction features of the designed linear Fresnel lens.
Fig. 2
Fig. 2 (a) Machined brass roller mold held on an ultra-precision machining system. (b) Schematic illustration showing the tool path and tool-workpiece setting for the machining process (Not drawn to scale).
Fig. 3
Fig. 3 (a) Close view of the measurement setup. (b) Measured surface profile of one linear Fresnel lens pattern. (c) Measurement process considering the shape of stylus tip. (d) Deviation of measured facet angles on the roller mold from the designed ones.
Fig. 4
Fig. 4 Schematic and physical views of the self-developed roll-to-roll UV embossing system.
Fig. 5
Fig. 5 (a) Measurement of R2R embossed linear Fresnel lens film using a stylus profilometer. (b) Measured 3D profile of one linear Fresnel lens pattern. (c) Deviation of measured facet angles on the Fresnel lens film from the designed ones.
Fig. 6
Fig. 6 (a) Measurement setup for light concentration test of linear Fresnel lens film (three identical lens patterns). (b) Measured concentration ratio with respect to the position of the referenced solar cell.

Equations (2)

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n c sin α i = n a sin β i
R= V f V d V 0 V d

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