Packaging structure of organic photovoltaic cells

Abstract

This utility model relates to the field of organic photovoltaic technology and discloses an encapsulation structure for an organic photovoltaic cell, comprising a substrate, an organic photovoltaic cell module, a sealant layer, and a cover plate. The organic photovoltaic cell module is located on the surface of the substrate and encapsulated within the space formed by the cover plate, the sealant layer, and the substrate. The organic photovoltaic cell module includes multiple cell units connected in series along a first direction. The surface of the cover plate facing the substrate is provided with multiple first strip grooves, all of which extend along a second direction. At least two of the first strip grooves are located on the outer sides of the cell units at both ends of the organic photovoltaic cell module. The first direction and the second direction are perpendicular to each other on the surface of the substrate facing the cover plate. The sealant layer is at least partially embedded in the first strip grooves to prevent glue overflow.

Description

Technical Field

[0001] This utility model relates to the field of organic photovoltaic technology, and specifically to an encapsulation structure for an organic photovoltaic cell. Background Technology

[0002] Organic photovoltaics (OPV), as a next-generation photovoltaic technology, possesses unique advantages such as flexibility, thinness, and transparency. It can overcome the limitations of traditional crystalline silicon photovoltaics in application scenarios, meeting the green energy needs of various fields including electronic equipment, transportation, and buildings. The functional layers of an OPV cell typically consist of a sequentially stacked anode, anode buffer layer, photoactive layer, cathode buffer layer, and cathode. Because the functional layer materials are highly sensitive to moisture and oxygen, effective encapsulation is essential for the industrial application of OPV cells to prevent contact with air, water, or oxygen, thereby improving device stability and lifespan.

[0003] Currently, the common encapsulation method for organic photovoltaic cells is as follows: first, the functional layer is prepared on the substrate; then, a sealant layer is applied to the top cover plate; finally, the top cover plate with the sealant layer is closed to the substrate, and encapsulation is completed through a lamination process. During this process, the sealant layer is prone to overflow under pressure, forming uneven sealant edges, which can contaminate the outer area of ​​the cell, affecting encapsulation accuracy and product consistency, and ultimately reducing manufacturing yield and long-term reliability. Utility Model Content

[0004] This invention provides an organic photovoltaic cell encapsulation structure to solve the problem of easy glue overflow in the sealing layer.

[0005] The present invention discloses an organic photovoltaic cell encapsulation structure, comprising a substrate, an organic photovoltaic cell module, a sealant layer, and a cover plate. The organic photovoltaic cell module is located on the surface of the substrate and encapsulated within the space formed by the cover plate, the sealant layer, and the substrate. The organic photovoltaic cell module includes multiple cell units connected in series along a first direction. The surface of the cover plate facing the substrate is provided with multiple first strip grooves, all of which extend along a second direction. At least two of the first strip grooves are located on the outer sides of the cell units at both ends of the organic photovoltaic cell module. The first direction and the second direction are perpendicular to each other on the surface of the substrate facing the cover plate. The sealant layer is at least partially embedded in the first strip grooves.

[0006] This invention effectively controls the overflow of the sealant layer by creating a first strip-shaped groove on the surface of the cover plate facing the substrate. This groove allows the sealant to be partially embedded, thus preventing overflow in the first direction. The principle is that during the encapsulation of organic photovoltaic cells, as the adhesive diffuses along the outer edge of the cell, some of it is introduced and contained within the first strip-shaped groove, where it is dispersed and confined. This not only guides the flow direction of the adhesive and suppresses overflow, preventing irregular adhesive residue from forming at the device edges, but also improves the uniformity and controllability of the sealing boundary, ensures consistent encapsulation contours, improves the appearance quality and dimensional accuracy of the device, thereby increasing the overall encapsulation yield.

[0007] Optionally, a plurality of second grooves are further formed on the surface of the cover plate facing the substrate. The second grooves extend along the first direction, and at least two of the second grooves are located on opposite sides of the organic photovoltaic cell module along the second direction. The purpose is to further limit the overflow of adhesive along the second direction through the second grooves.

[0008] Optionally, there are two of each of the first and second strip grooves. The second strip groove and the first strip groove together form a square. The second strip groove and the first strip groove are connected, and the organic photovoltaic cell module is located within the square.

[0009] Optionally, the organic photovoltaic cell module includes n cell units connected in series. Each cell unit includes a lower electrode layer, an upper electrode layer, and a functional layer located between the lower electrode layer and the upper electrode layer. The lower electrode layer is located on a substrate, and n is greater than or equal to 2.

[0010] Optionally, the organic photovoltaic cell encapsulation structure further includes two or more electrode extraction portions, which are located on the surface of the substrate facing the cover plate and are integrally formed with the upper electrode layer.

[0011] Optionally, two electrode extraction portions are provided, and the two electrode extraction portions are respectively located on the outside of the battery cells at both ends of the organic photovoltaic cell module along the first direction. Optionally, the first strip groove includes an arc groove, a V-shaped groove, or a trapezoidal groove.

[0012] Optionally, the distance between the edge of the first strip away from the organic photovoltaic cell module and the corresponding side edge of the cover plate is 0mm~2mm.

[0013] Optionally, the depth of the first groove is 10μm to 100μm.

[0014] Optionally, the width of the first groove is 0.1mm to 0.5mm. Attached Figure Description

[0015] To more clearly illustrate the specific embodiments of this utility model or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0016] Figure 1 This is a front view schematic diagram of the packaging structure according to an embodiment of the present utility model; Figure 2 This is a schematic diagram of the cover plate of this utility model embodiment, showing only the first strip groove. Figure 3 The packaging structure of this embodiment only applies the edge of the first strip groove. Figure 1 Half-section view in the first direction; Figure 4 The packaging structure of this embodiment only applies the edge of the first strip groove. Figure 1 Second half-section view in the middle direction; Figure 5 The cover plate of this utility model embodiment is in Figure 2 A schematic diagram of a structure with a second strip groove added to the existing structure; Figure 6 The encapsulation structure of this utility model embodiment includes the second strip groove along its edge. Figure 1 Half-section view in the first direction; Figure 7 The encapsulation structure of this utility model embodiment includes the second strip groove along its edge. Figure 1 Second half-section view in the middle direction; Figure 8 This is a dimensioned diagram of the strip groove on the cover plate according to an embodiment of the present utility model.

[0017] Explanation of reference numerals in the attached figures: 1. Substrate; 2. Cover plate; 3. Battery cell; 301. Upper electrode layer; 302. Lower electrode layer; 303. Functional layer; 4. First strip groove; 5. Second strip groove; 6. Electrode extraction part; 601. Electrode extraction part connection part; 602. Electrode extraction part end; 7. Sealant layer; 8. Insulating channel; 9. Connecting channel; 10. Isolation channel. Detailed Implementation

[0018] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0019] It should be noted that the terms "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", and "outer" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0020] The terms "parallel" and "perpendicular" include the described situation and situations similar to the described situation, where the range of similarity is within an acceptable deviation range, which is determined by those skilled in the art taking into account the measurement under discussion and the error associated with the measurement of a particular quantity (i.e., the limitations of the measurement system). For example, "parallel" includes absolute parallelism and approximate parallelism, where the acceptable deviation range for approximate parallelism can be, for example, within 5°; "perpendicular" includes absolute perpendicularity and approximate perpendicularity, where the acceptable deviation range for approximate perpendicularity can also be, for example, within 5°. Those skilled in the art will understand the specific meaning of the above terms in this application based on the specific circumstances.

[0021] The "battery unit" described in this application is an organic photovoltaic cell unit. In this embodiment, reference is made to... Figure 1 , Figure 2 , Figure 3 as well as Figure 4 The encapsulation structure of the organic photovoltaic cell includes a substrate 1, an organic photovoltaic cell module, a sealant layer 7, and a cover plate 2. The organic photovoltaic cell module is located on the surface of the substrate 1 and is encapsulated in the space enclosed by the cover plate 2, the sealant layer 7, and the substrate 1.

[0022] The organic photovoltaic cell module includes multiple battery cells 3 connected in series along a first direction. The cover plate 2 has multiple first strip grooves 4 on its surface facing the substrate 1. The first strip grooves 4 all extend along a second direction. At least two of the first strip grooves 4 are located on the outer sides of the battery cells 3 at both ends of the organic photovoltaic cell module. The first direction and the second direction are perpendicular to each other on the surface of the substrate 1 facing the cover plate 2. The sealant layer 7 is at least partially embedded in the first strip grooves 4.

[0023] In an optional embodiment, the cover plate 2 has two first strip grooves 4 on its surface facing the substrate 1, and the two first strip grooves 4 are respectively located on the outside of the battery cells 3 at both ends of the organic photovoltaic cell module along the first direction.

[0024] Therefore, in this embodiment, when the cover plate 2 coated with sealant is placed on the substrate 1 on which the organic photovoltaic cell module is prepared, and lamination or rolling is performed, some of the adhesive will be embedded in the first groove 4 and confined to the area between the first groove 4, thereby forming a controlled adhesive coating area.

[0025] Understandably, in combination Figure 3 Excess adhesive will be guided and filled into the internal space of the first groove 4, thereby effectively absorbing and accommodating the volume of adhesive that is about to overflow, and weakening its kinetic energy and flow tendency to a certain extent, inhibiting the adhesive from continuing to spread across the first groove 4 to the edge of the cover plate 2, thereby improving the neatness and reliability of the encapsulation.

[0026] In this embodiment, the substrate 1 can be roughly rectangular in shape, the first direction can be the long side direction of the substrate 1, and the second direction can be the short side direction of the substrate 1.

[0027] In one embodiment, reference Figure 5 , Figure 6 and Figure 7 The cover plate 2 also has a plurality of second strip grooves 5 formed on its surface facing the substrate 1. These second strip grooves 5 extend along the first direction, and at least two of the second strip grooves 5 are located on either side of the organic photovoltaic cell module along the second direction. This is to further intercept any small amount of adhesive that may diffuse along the second direction.

[0028] Based on the above technical features, if it is necessary to further improve the glue limiting effect in actual production according to different cover plate 2 shapes or glue overflow trends, the above-mentioned second strip groove 5 can be selectively added. For example, when the sealant layer 7 overflows significantly relative to the cover plate 2 in the second direction, the second strip groove 5 can be added at the corresponding position to further improve the encapsulation uniformity and the control accuracy of the sealant layer 7.

[0029] In one embodiment, review Figure 5 There can be two of the first strip groove 4 and the second strip groove 5. The second strip groove 5 and the first strip groove 4 together form a square. At the same time, the second strip groove 5 and the first strip groove 4 are connected, so that when the glue is pushed by the extrusion force and diffuses in multiple directions, it can be effectively guided and concentrated into the square annular groove.

[0030] In one embodiment, the organic photovoltaic cell module includes n battery cells 3 connected in series. Each battery cell 3 includes a lower electrode layer 302, an upper electrode layer 301, and a functional layer 303 located between the lower electrode layer 302 and the upper electrode layer 301. The lower electrode layer 302 is located on the upper surface of the substrate 1, where n is selected from an integer greater than or equal to 2.

[0031] In this embodiment, reference Figure 3 and Figure 6 The n battery cells 3 can be connected in series through a channel assembly, which consists of an insulating channel 8, a connecting channel 9, and a blocking channel 10.

[0032] In one embodiment, the insulating channel 8 is located between the functional layer 303 and the substrate 1 and penetrates the lower electrode layer 302, the connecting channel 9 is located between the upper electrode layer 301 and the lower electrode layer 302 and penetrates the functional layer 303, and the blocking channel 10 penetrates at least the upper electrode layer 301 but cannot penetrate the lower electrode layer 302.

[0033] In one embodiment, n is selected from an integer greater than or equal to 3; in another embodiment, n is selected from an integer greater than or equal to 4; in another embodiment, n is selected from an integer greater than or equal to 5; in another embodiment, n is selected from an integer greater than or equal to 6; in another embodiment, n is selected from an integer greater than or equal to 9; in another embodiment, n is selected from an integer greater than or equal to 15; in another embodiment, n is selected from an integer greater than or equal to 20. The number of battery cells 3 can be specifically selected according to the performance requirements of the product application.

[0034] In a preferred embodiment, the functional layer 303 includes an anode buffer layer, a photoactive layer, and a cathode buffer layer stacked thereon.

[0035] In one embodiment, such as Figure 3 and Figure 6 As shown, the organic photovoltaic cell encapsulation structure further includes two or more electrode extraction sections 6. These electrode extraction sections 6 are located on the surface of the substrate 1 facing the cover plate 2 and are integrally formed with the upper electrode layer 301 of the cell unit in the organic photovoltaic cell module. The electrode extraction sections 6 are used to bring out the cathode and anode of the organic photovoltaic module for integration with external devices.

[0036] It should be noted that "one-piece molding" refers to the use of the same process and materials to prepare the same structure as a whole.

[0037] Furthermore, two electrode extraction parts 6 are provided, and the two electrode extraction parts 6 are respectively located on the outside of the battery cells 3 at both ends of the organic photovoltaic cell module along the first direction.

[0038] Furthermore, the electrode removal part 6 may include an electrode removal part connecting part 601 and an electrode removal part end 602. The electrode removal part connecting part 601 is connected to the upper electrode layer 301, and the electrode removal part end 602 is located on the outer side of the cover plate 2 along the first direction.

[0039] In other words, reference Figure 1 The edges of the cover plate 2 on both sides in the first direction abut against the surface of the electrode extraction part connecting part 601 facing away from the substrate 1, thereby making the electrode extraction part 6 have an exposed electrode extraction part end 602. This facilitates the electrical integration of the packaged organic photovoltaic module with external devices through the electrode extraction part 6.

[0040] Further, refer to Figure 1 The edge of the electrode extraction end 602 can be flush with the side edge of the substrate 1 in the first direction. At the same time, the length of the cover plate 2 in the first direction can be set to be less than the length of the substrate 1 in that direction, so as to ensure that the electrode extraction end 602 is located outside the cover plate 2, thereby achieving its exposed setting.

[0041] In this embodiment, reference Figure 3 , Figure 6 and Figure 7 The cross-sections of the first strip groove 4 and the second strip groove 5 can have any suitable shape, preferably an arc-shaped groove, a V-shaped groove, or a trapezoidal groove. Furthermore, the number of the first strip groove 4 and the second strip groove 5 can be adaptively adjusted according to actual production needs.

[0042] The arc-shaped groove refers to a groove structure in which the cross-section (shape of the groove opening) is at least partially arc-shaped. The groove can be a circular arc groove, such as a semi-circular groove, or an elliptical arc groove, such as a U-shaped groove.

[0043] In this embodiment, pre-cut cover plate 2 and substrate 1 can be directly used for encapsulation, or multiple organic photovoltaic cells can be fabricated through patterning, and then the cover plate 2 and substrate 1 can be cut into individual devices using laser technology. The presence or absence of a sealant layer 7 in the cutting area has a decisive impact on the yield. If the sealant layer 7 overflows into this area, it will solidify, making laser cutting extremely difficult, and irregular adhesive-like substances will form at the cutting edges, causing the final device size to deviate significantly from the predetermined specifications.

[0044] Therefore, the first groove 4 in this embodiment also prevents adhesive from flowing into the cutting area between the cover plate 2 and the substrate 1. This adhesive-limiting structure avoids a series of problems caused by sealant overflow at the source, including cutting difficulties during laser cutting, irregular adhesive residue at the edges, and deviations in finished product dimensions from predetermined specifications. This not only significantly improves the product yield but also effectively ensures the consistency of device dimensions and appearance quality. Furthermore, when the substrate 1 needs to be circumferentially cut during the manufacturing process, a second groove 5 can be added according to actual needs, or the amount of sealant layer 7 can be precisely controlled to limit adhesive overflow in the long side direction, thereby achieving more precise sealant control while maintaining process flexibility.

[0045] In one embodiment, both the cover plate 2 and the substrate 1 are selected from glass.

[0046] Furthermore, the thickness of the cover plate 2 is selected from 0.4 mm to 5 mm.

[0047] Furthermore, the thickness of the cover plate 2 is selected from 0.4 mm to 3 mm.

[0048] Furthermore, the thickness of the cover plate 2 is selected from 0.4 mm to 1.1 mm.

[0049] In one embodiment, the thickness of the substrate 1 is selected from 0.4 mm to 5 mm.

[0050] Furthermore, the thickness of the substrate 1 is selected from 0.4 mm to 3 mm.

[0051] Furthermore, the thickness of the substrate 1 is selected from 0.4 mm to 1.1 mm.

[0052] refer to Figure 8In the encapsulation structure of this embodiment, to ensure optimal encapsulation effect, the geometric dimensions of the first strip groove 4 on the upper cover plate 2 are precisely defined. Referring to the figure, the distance (d2) between the outer edge of the first strip groove 4 and the edge of the cover plate 2 should not be too large. This is because, given that the overall size of the organic photovoltaic cell is fixed, an excessively large d2 will encroach on the effective encapsulation area, thereby affecting the long-term protection effect on the internal functional areas. Therefore, the value range of d2 is limited to 0 to 2 mm, with a preferred range of 0.1 to 0.3 mm.

[0053] Meanwhile, the dimensions of the first groove 4 itself, namely the groove depth (h) and groove width (d1), also need to be within a balanced range. The core function of the first groove 4 is to provide a reserved space to accommodate the sealant layer 7 that overflows during lamination. If the first groove 4 is too shallow or the groove width (d1) is too narrow, its volume will not be sufficient to completely contain the excess sealant, leading to interception failure. Conversely, if the first groove 4 is etched too deeply, it will weaken the glass thickness at that location, forming a structural weak point and increasing the risk of the cover plate 2 cracking under lamination pressure. If the first groove 4 is too wide, it will unnecessarily reduce the effective encapsulation area. Based on the above considerations, in this embodiment, the groove depth (h) is set to a range of 10μm to 100μm, preferably 20μm to 60μm; the groove width (d1) is set to a range of 0.1mm to 0.5mm.

[0054] It should be noted that if a second strip groove 5 is added, the size of the second strip groove 5 can be the same as the size of the first strip groove 4.

[0055] Therefore, based on the encapsulation structure of this embodiment, the production of organic photovoltaic cells can be carried out by following these steps in sequence: S1, a lower electrode layer 302 is prepared on the substrate 1 by vapor deposition or sputtering process, and then an insulating channel 8 is etched through the lower electrode layer 302 to the substrate 1 by laser process.

[0056] S2, a functional layer 303 is prepared on the lower electrode layer 302 by vapor deposition and / or coating process, and then a connecting channel 9 is etched through the functional layer 303 to the lower electrode layer 302 by laser process.

[0057] S3: Reference Figure 2 and Figure 3 The lower electrode layer 302 and functional layer 303 around the periphery of the substrate 1 are removed by laser etching, thereby reserving a clean space for subsequent sealing and electrode removal part 6.

[0058] S4: The upper electrode layer 301 and the electrode extraction part 6 are prepared by vapor deposition or sputtering process, and the isolation channel 10 is etched on it by laser process. The channel at least cuts through the upper electrode layer 301, thus completing the main body of the organic photovoltaic cell to be packaged.

[0059] S5: The first groove 4 is etched on the cover plate 2 using a laser process, and then a sealant layer 7 is applied to the adhesive application area defined by the first groove 4 using a screen printing or dispensing process. If a second groove 5 needs to be added, it is etched in this step using a laser process.

[0060] S6: The cover plate 2 containing the sealant layer 7 prepared in S5 is tightly bonded to the organic photovoltaic cell body to be encapsulated prepared in S4 by rolling or lamination.

[0061] If the patterning process described above is used, then the following additional steps are added to the above steps S1-S6: S7. Using laser technology, the cover plate 2 is scribed and cut on the upper side of the electrode extraction part connection part 601 according to the size of the cover plate 2 of a single device. This laser etching only cuts the upper cover plate 2, the purpose of which is to make the length of the finally formed upper cover plate 2 in the first direction less than that of the substrate 1, thereby ensuring that the end 602 of the electrode extraction part can be exposed on the outside of the cover plate 2.

[0062] S8. Using laser technology, lines are drawn according to the size of the substrate 1 of each individual device, separating the fully packaged device into multiple independent, well-packaged organic photovoltaic cells.

[0063] Although embodiments of the present invention have been described in conjunction with the accompanying drawings, those skilled in the art can make various modifications and variations without departing from the spirit and scope of the present invention, and such modifications and variations all fall within the scope defined by the appended claims.

Claims

1. An encapsulation structure of an organic photovoltaic cell, comprising a substrate (1), an organic photovoltaic cell module, a sealant layer (7), and a cover plate (2), the organic photovoltaic cell module being located on a surface of the substrate (1) and being encapsulated in a space surrounded by the cover plate (2), the sealant layer (7), and the substrate (1), characterized in that, The organic photovoltaic cell module includes multiple cell units (3), which are connected in series along a first direction. The cover plate (2) has multiple first strip grooves (4) on its surface facing the substrate (1), and the first strip grooves (4) all extend along a second direction. At least two of the first strip grooves (4) are located on the outside of the battery cells (3) at both ends of the organic photovoltaic cell module. The first direction and the second direction are perpendicular to each other on the surface of the substrate (1) facing the cover plate (2). The sealant layer (7) is at least partially embedded in the first strip groove (4).

2. The encapsulation structure of an organic photovoltaic cell according to claim 1, wherein The cover plate (2) also has a plurality of second strip grooves (5) formed on its surface facing the substrate (1). The second strip grooves (5) extend along the first direction, and at least two of the second strip grooves (5) are located on both sides of the organic photovoltaic cell module along the second direction.

3. The encapsulation structure of an organic photovoltaic cell according to claim 2, wherein There are two of the first strip groove (4) and the second strip groove (5). The second strip groove (5) and the first strip groove (4) together form a square. The second strip groove (5) and the first strip groove (4) are connected. The organic photovoltaic cell module is located inside the square.

4. The encapsulation structure of the organic photovoltaic cell according to claim 1, characterized in that, The organic photovoltaic cell module includes n series-connected cell units (3). Each cell unit (3) includes a lower electrode layer (302), an upper electrode layer (301), and a functional layer (303) located between the lower electrode layer (302) and the upper electrode layer (301). The lower electrode layer (302) is located on a substrate (1), where n is an integer greater than or equal to 2.

5. The encapsulation structure of the organic photovoltaic cell according to claim 4, characterized in that, The organic photovoltaic cell encapsulation structure also includes two or more electrode extraction parts (6), which are located on the surface of the substrate (1) facing the cover plate (2) and are integrally formed with the upper electrode layer (301).

6. The encapsulation structure of the organic photovoltaic cell according to claim 5, characterized in that, Two electrode extraction parts (6) are provided, and the two electrode extraction parts (6) are respectively located on the outside of the battery cells (3) at both ends of the organic photovoltaic cell module along the first direction.

7. The encapsulation structure of the organic photovoltaic cell according to claim 1, characterized in that, The first strip groove (4) includes an arc groove, a V-shaped groove or a trapezoidal groove.

8. The encapsulation structure of the organic photovoltaic cell according to claim 1, characterized in that, The distance between the edge of the first groove (4) away from the organic photovoltaic cell and the corresponding side edge of the cover plate (2) is 0mm~2mm.

9. The encapsulation structure of the organic photovoltaic cell according to claim 8, characterized in that, The groove depth of the first strip groove (4) is 10μm~100μm.

10. The encapsulation structure of the organic photovoltaic cell according to claim 9, characterized in that, The width of the first strip groove (4) is 0.1mm~0.5mm.

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