# US 2009/0025784 A1 · Thermal spray for solar concentrator fabrication > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2009/0025784 A1 - Document ID: US20090025784A1 - Status: Published application - Kind: A1 - Application number: 11/782,605 - Filed: 2007-07-24 - Published: 2009-01-29 - Earliest claimed: 2007-02-02 - Assignees: Sol Focus, Inc.; Palo Alto Research Center Incorporated - Inventors: Hing Wah Chan; John S. Fitch; Michael C. Weisberg; David G. Duff - Web page: https://patentgrep.com/patent/US20090025784A1 ## CPC - H10F 77/42: directly associated or integrated with photovoltaic cells, e.g. light-reflecting means or light-concentrating means - H10F 77/488: {Reflecting light-concentrating means, e.g. parabolic mirrors or concentrators using total internal reflection} - H10W 72/252: {comprising solid metals or solid metalloids, e.g. PbSn, Ag or Cu} - H10W 72/90: Bond pads, in general - H10W 72/923: {Bond pads having multiple stacked layers} - H10W 72/9415: {relative to the surface, e.g. recessed, protruding} - H10W 90/724: {between a chip and a stacked insulating package substrate, interposer or RDL} - Y02E 10/52: PV systems with concentrators - Y10T 156/10: Methods of surface bonding and/or assembly therefor - H10F: INORGANIC SEMICONDUCTOR DEVICES SENSITIVE TO INFRARED RADIATION, LIGHT, ELECTROMAGNETIC RADIATION OF SHORTER WAVELENGTH OR CORPUSCULAR RADIATION - H10W: GENERIC PACKAGES, INTERCONNECTIONS, CONNECTORS OR OTHER CONSTRUCTIONAL DETAILS OF DEVICES COVERED BY CLASS H10 - Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A system may include an optical element, a thermal-sprayed material disposed on the optical element, and a solar cell coupled to the optical element. Some aspects provide thermal spraying of a first material onto an optical element, and coupling of a solar cell to the optical element. Thermal spraying the first material may include spraying a molten metal powder onto the optical element. ## Claims ### Claim 1 A method comprising: thermal spraying a first material onto an optical element; and coupling a solar cell to the optical element. ### Claim 2 (depends on 1) A method according to claim 1, wherein thermal spraying the first material comprises spraying a molten metal powder onto the optical element. ### Claim 3 (depends on 2) A method according to claim 2, wherein spraying the molten metal powder onto the optical element comprises: placing a stencil on the optical element; and spraying a molten metal powder onto the stencil and the optical element. ### Claim 4 (depends on 3) A method according to claim 3, further comprising: removing the stencil to expose an aperture from which light may pass out of the optical element, wherein coupling the solar cell to the optical element comprises: coupling an electrical contact of the solar cell to the first material to align an optically-active area of the solar cell with the aperture. ### Claim 5 (depends on 3) A method according to claim 3, wherein the stencil comprises a mechanical, hard or soft tooling. ### Claim 6 (depends on 1) A method according to claim 1, wherein thermal spraying the first material comprises powder coating a polymer onto the optical element. ### Claim 7 (depends on 1) A method according to claim 1, further comprising: depositing a reflective material on a substantially-transparent core; and depositing an insulator on the reflective material; wherein thermal spraying the first material comprises spraying a molten metal powder onto the insulator. ### Claim 8 (depends on 7) A method according to claim 7, wherein depositing the insulator comprises powder coating a polymer onto the reflective material. ### Claim 9 (depends on 7) A method according to claim 7, wherein depositing the reflective material comprises physical vapor deposition of the reflective material onto the substantially-transparent core. ### Claim 10 (depends on 7) A method according to claim 7, wherein thermal spraying the first material comprises: placing a stencil on the insulator; and spraying a molten metal powder onto the stencil and the insulator. ### Claim 11 (depends on 1) A method according to claim 1, wherein thermal spraying the first material onto the optical element comprises: placing a stencil on the optical element; and spraying the first material onto the stencil and the optical element. ### Claim 12 (depends on 1) A method according to claim 1, wherein coupling the solar cell to the optical element comprises coupling an electrical contact of the solar cell to the first material to align an optically-active area of the solar cell with an aperture from which light may pass out of the optical element. ### Claim 13 An apparatus comprising: an optical element; a thermal-sprayed material disposed on the optical element; and a solar cell coupled to the optical element. ### Claim 14 (depends on 13) An apparatus according to claim 13, wherein the thermal-sprayed material comprises a hardened metal powder. ### Claim 15 (depends on 14) An apparatus according to claim 14, wherein: the optical element comprises an aperture from which light may pass out of the optical element, an electrical contact of the solar cell is coupled to the hardened metal powder, and an optically-active area of the solar cell is aligned with the aperture. ### Claim 16 (depends on 13) An apparatus according to claim 13, wherein the thermal-sprayed material comprises a polymer. ### Claim 17 (depends on 13) An apparatus according to claim 13, wherein the optical element comprises: a substantially-transparent core; a reflective material disposed on the substantially-transparent core; and an insulator disposed on the reflective material, wherein the thermal-sprayed material is disposed on the insulator. ### Claim 18 (depends on 17) An apparatus according to claim 17, wherein the insulator comprises a powder-coated polymer. ### Claim 19 (depends on 13) An apparatus according to claim 13, wherein: the optical element comprises an aperture from which light may pass out of the optical element, an electrical contact of the solar cell is coupled to the thermal-sprayed material, and an optically-active area of the solar cell is aligned with the aperture.