We report the synthesis and characterization of a polymer thin-film structure consisting of two intersecting broadband optical waveguide lattices, and its performance in wide-angle optical energy collection and conversion in silicon solar cells. The structures are synthetically organized via the concurrent irradiation of photoreactive polymer blends by two arrays of intersecting, microscale optical beams transmitted through the medium. Through optical beam-induced photopolymerization and photopolymerization-induced phase separation, well-organized lattices are produced comprising of cylindrical core–cladding waveguide architectures that intersect one another. The optical waveguide properties of the lattices transform the transmission characteristics of the polymer film so that incident optical energy is collected and transmitted along the waveguide axes, rather than their natural directions dictated by refraction, thereby creating efficient light-collecting capability. The embedded structures collectively impart their wide-angle acceptance ranges to enable the film to efficiently collect and interact with light over a large angular range (±70°). When employed as the encapsulant material for a commercial silicon solar cell, the novel light collection and transmission properties result in greater wide-angle conversion efficiency and electrical current density, compared to a single vertically aligned waveguide array. The sustained and greater conversion of light afforded by the encapsulating optical material promises to increase solar cell performance by enabling ultrawide-angle solar energy conversion.

We present a theoretical study of the organization of photoreactive polymer blends under irradiation by multiple arrays of intersecting optical beams. In a simulated medium possessing an integrated intensity-dependent refractive index, optical beams undergo self-focusing and reduced divergence. A corresponding intensity-dependent increase in molecular weight induces polymer blend instability and consequent phase separation, whereby the medium can evolve into an intersecting waveguide lattice structure, comprising high refractive index cylindrical cores and a surrounding low refractive index medium (cladding). We conduct simulations for two propagation angles and a range of thermodynamic, kinetic, and polymer blend parameters to establish correlations to structure and morphology. We show that spatially correlated structures, namely, those that have a similar intersecting three-dimensional (3D) pattern as the arrays of intersecting optical beams, are achieved via a balance between the competitive processes of photopolymerization rate and phase separation dynamics. A greater intersection angle of the optical beams leads to higher correlations between structures and the optical beam pattern and a wider parameter space that achieves correlated structures. This work demonstrates the potential to employ complex propagating light patterns to create 3D organized structures in multicomponent photoreactive soft systems.

We present the properties and performance of fluorescent waveguide lattices as coatings for solar cells, designed to address the significant mismatch between the solar cell’s spectral response range and the solar spectrum. Using arrays of microscale visible light optical beams transmitted through photoreactive polymer resins comprising acrylate and silicone monomers and fluorescein o,o′-dimethacrylate comonomer, we photopolymerize well-structured films with single and multiple waveguide lattices. The materials exhibited bright green-yellow fluorescence emission through down-conversion of blue-UV excitation and light redirection from the dye emission and waveguide lattice structure. This enables the films to collect a broader spectrum of light, spanning UV–vis–NIR over an exceptionally wide angular range of ±70°. When employed as encapsulant coatings on commercial silicon solar cells, the polymer waveguide lattices exhibited significant enhancements in solar cell current density. Below 400 nm, the primary mode of enhancement is through down-conversion and light redirection from the dye emission and collection by the waveguides. Above 400 nm, the primary modes of enhancement were a combination of down-conversion, wide-angle light collection, and light redirection from the dye emission and collection by the waveguides. Waveguide lattices with higher dye concentrations produced more well-defined structures better suited for current generation in encapsulated solar cells. Under standard AM 1.5 G irradiation, we observed nominal average current density increases of 0.7 and 1.87 mA/cm2 for single waveguide lattices and two intersecting lattices, respectively, across the full ±70° range and reveal optimal dye concentrations and suitable lattice structures for solar cell performance. Our findings demonstrate the significant potential of incorporating down-converting fluorescent dyes in polymer waveguide lattices for improving the current spectral and angular response of solar cell technologies toward increasing clean energy in the energy grid.