We report a study on the growth kinetics and resultant structures of arrays of pillars in photo-cross-linkable films during irradiation with a periodic array of microscale optical beams under ambient conditions. The optical beams experience a self-focusing nonlinearity owing to the photopolymerization-induced changes in refractive index, thereby concentrating light and driving the concurrent, parallel growth of microscale pillars along their path length. We demonstrate control over the pillar spacing and pillar height with the irradiation intensity, film thickness, and the size and spacing of the optical beams. The growth of individual pillars in a periodic array arises from the combination of intense irradiation in the beam regions and oxygen inhibition afforded by the open, ambient conditions under which growth is carried out. We propose a kinetic model for pillar growth that includes free-radical generation and oxygen inhibition in thick films of photoinitiated media in order to interpret the experimental results. The model effectively correlates micropillar array structure to the oxygen inhibition effects. This approach of growing micropillar arrays through photopolymerization is straightforward and scalable and opens opportunities for the design of textured surfaces for applications.

The fabrication of a new type of solar cell encapsulation architecture comprising a periodic array of step-index waveguides is reported. The materials are fabricated through patterning with light in a photoreactive binary blend of crosslinking acrylate and urethane, wherein phase separation induces the spontaneous, directed formation of broadband, cylindrical waveguides. This microstructured material efficiently collects and transmits optical energy over a wide range of entry angles. Silicon solar cells comprising this encapsulation architecture show greater total external quantum efficiencies and enhanced wide-angle light capture and conversion. This is a rapid, straightforward, and scalable approach to process light-collecting structures, whereby significant increases in cell performance may be achieved.

Silicon solar cells are the most widely deployed modules owing to their low-cost manufacture, large market, and suitable efficiencies for residential and commercial use. Methods to increase their solar energy collection must be easily integrated into module fabrication. We perform a theoretical and experimental study on the light collection properties of an encapsulant that incorporates a periodic array of air prisms, which overlay the metallic front contacts of silicon solar cells. We show that the light collection efficiency induced by the encapsulant depends on both the shape of the prisms and angle of incidence of incoming light. We elucidate the changes in collection efficiency in terms of the ray paths and reflection mechanisms in the encapsulant. We fabricated the encapsulant from a commercial silicone and studied the change in the external quantum efficiency (EQE) on an encapsulated, standard silicon solar cell. We observe efficiency enhancements, as compared to a uniform encapsulant, over the visible to near infrared region for a range of incident angles. This work demonstrates exactly how a periodic air prism architecture increases light collection, and how it may be designed to maximize light collection over the widest range of incident angles.

Calcium batteries are promising alternatives to lithium batteries owing to their high energy density, comparable reduction potential, and mineral abundance. However, to meet practical demands in high-performance applications, suitable electrolytes must be developed. Here, we report the synthesis and characterization of polymer gel electrolytes for calcium-ion conduction prepared by the photo-cross-linking of poly(ethylene glycol) diacrylate (PEGDA) in the presence of solutions of calcium salts in a mixture of ethylene carbonate (EC) and propylene carbonate (PC) solvents. The results show room-temperature conductivity between 10 −5 and 10 −4 S/cm, electrochemical stability windows of ∼3.8 V, full dissociation of the salt, and minimal coordination with the PEGDA backbone. Cycling in symmetric Ca metal cells proceeds but with increasing overpotentials, which can be attributed to interfacial impedance between the electrolyte and calcium surface, which inhibits charge transfer. Calcium may still be plated and stripped yielding high-purity deposits and no indication of significant electrolyte breakdown, indicating that high overpotentials are associated with an electrically insulating, yet ion-permeable solid electrolyte interface (SEI). This work provides a contribution to the study and understanding of polymer gel materials toward their improvement and application as electrolytes for calcium batteries.

A new approach is reported to fabricate micropillar arrays on transparent surfaces by employing the light‐induced self‐writing technique. A periodic array of microscale optical beams is transmitted through a thin film of photo‐crosslinking acrylate resin. Each beam undergoes self‐lensing associated to photopolymerization‐induced changes in the refractive index of the medium, which counters the beam's natural tendency to diverge over space. As a result, a microscale pillar grows along each beam's propagation path. Concurrent, parallel self‐writing of micropillars leads to the prototyping of micropillar‐based arrays, with the capability to precisely vary the pillar diameter and inter‐spacing. The arrays are spray coated with a thin layer of polytetrafluoroethylene (PTFE) nanoparticles to create large‐area superhydrophobic surfaces with water contact angles greater than 150° and low contact angle hysteresis. High transparency is achieved over the entire range of micropillar arrays explored. The arrays are also mechanically durable and robust against abrasion. This is a scalable, straightforward approach toward structure‐tunable micropillar arrays for functional surfaces and anti‐wetting applications.