Reflective microstructured films with microstructures having curved surfaces, for use in solar modules

Patent metadata

Field	Value
Publication number	US-2016172518-A1
Application number	US-201414902876-A
Country	US
Kind code	A1
Filing date	Jun 26, 2014
Priority date	Jul 9, 2013
Publication date	Jun 16, 2016
Grant date	—

Abstract

Reflective microstructured films include a base layer, and an ordered arrangement of a plurality of microstructures projecting from the base layer. The microstructures have a cross section with at least two sides, at least one of these sides is a curved surface. Each curved surface is defined by an angle of curvature. Additionally, the microstructures include a reflective layer. These reflective microstructured films can be used in solar modules.

First claim

What is claimed is:

1 . A reflective film comprising:
a base layer; and an ordered arrangement of a plurality of microstructures projecting from the base layer, the microstructures having a cross section comprising at least two sides, wherein at least one of the sides comprises a curved surface defined by an angle of curvature, and wherein the microstructures comprise a reflective layer.

2 . The reflective film of claim 1 , wherein the microstructures protrude 5 micrometers to 500 micrometers from the base layer.

3 . The reflective film of claim 1 , wherein all of the at least two sides comprise curved surfaces, and wherein the angle of curvature of the curved surfaces is the same.

4 . The reflective film of claim 1 , wherein the angle of curvature is greater than 0° and less than or equal to 9°.

5 . The reflective film of claim 1 , wherein the base layer comprises a polymeric layer.

6 . The reflective film of claim 1 , wherein the microstructures comprise a polymeric material.

7 . The reflective film of claim 6 , wherein the microstructures comprise the same polymeric material as the base layer.

8 . The reflective film of claim 6 , wherein the microstructures comprise a different polymeric from the base layer.

9 . The reflective film of claim 1 , wherein the reflective layer comprises a metallic coating.

10 . The reflective film of claim 9 , wherein the metallic coating comprises aluminum, silver, or a combination thereof.

11 . The reflective film of claim 1 , wherein the peaks of the microstructures are rounded.

12 . A solar module comprising:
a plurality of solar cells; and a reflective film, the reflective film comprising:
a base layer; and
an ordered arrangement of a plurality of microstructures projecting from the base layer, the microstructures having a cross section comprising at least two sides wherein at least one of the sides comprises a curved surface defined by an
angle of curvature, and wherein the microstructures comprise a reflective layer.

13 . The solar module of claim 12 , wherein the microstructures protrude 5 micrometers to 500 micrometers from the base layer.

14 . The solar module of claim 12 , wherein the angle of curvature is greater than 0° and less than or equal to 9°.

15 . The solar module of claim 12 , wherein the reflective layer comprises a metallic coating.

16 . The solar module of claim 12 , wherein the reflective film is located adjacent to the solar cells and/or adjacent to tabbing ribbons connecting the solar cells.

17 . A method of preparing a solar module comprising:
providing a reflective film, the reflective film comprising:
a base layer; and
an ordered arrangement of a plurality of microstructures projecting from the base layer, the microstructures having a cross section comprising at least two
sides wherein at least one of the sides comprises a curved surface defined by an
angle of curvature, and wherein the microstructures comprise a reflective layer;
providing a plurality of solar cells arranged on a support substrate and connected by tabbing ribbons; attaching the reflecting film to the solar cells and/or adjacent areas; and attaching a transparent cover layer over the reflecting film.

18 . The method of claim 17 , wherein the microstructures protrude 5 micrometers to 500 micrometers from the base layer.

19 . The method of claim 17 , wherein the angle of curvature is greater than 0° and less than or equal to 9°.

20 . The method of claim 17 , wherein the reflective layer comprises a metallic coating.

21 . The method of claim 20 , wherein the metallic coating comprises aluminum, silver, or a combination thereof.

22 . The method of claim 17 , wherein the peaks of the microstructures are rounded.

23 . The method of claim 17 , wherein the reflecting film is attached adjacent to at least a portion of the tabbing ribbons.

Assignees

• 3M Innovative Properties Co

Inventors

• Ma Jiaying
• Strharsky Roger J

Classifications

• H10F77/707

  of the substrates or of layers on substrates, e.g. textured ITO layer on a glass substrate · CPC title

• H10F77/48 Primary

  Back surface reflectors [BSR] · CPC title

• G02B19/0019

  having reflective surfaces only (e.g. louvre systems, systems with multiple planar reflectors) · CPC title

• G02B5/0866

  incorporating one or more organic, e.g. polymeric layers · CPC title

• H01L31/02366

  Electricity · mapped topic