Perovskite solar module and manufacturing method thereof

Abstract

A manufacturing method of a perovskite solar module comprises: a first step of forming a light-transmitting conductive film on a first substrate by vacuum coating; a second step of forming a first carrier transport film on the light-transmitting conductive film by vacuum coating; a third step of forming a perovskite film on the first carrier transport film by vacuum coating; a fourth step of forming a second carrier transport film on the perovskite film by vacuum coating; a fifth step of forming a first conductive film on the second carrier transport film by vacuum coating; a sixth step of providing a second conductive film on the first substrate; a seventh step of packaging the first substrate with a packaging material; and an eighth step of providing a second substrate on the packaging material to obtain the perovskite solar module.

Description

Technical Field

[0001] The present invention relates to a solar cell, and in particular to a perovskite solar module and a manufacturing method thereof. Prior Art

[0002] Solar cells using perovskite as their core material are currently the thin-film solar cells with the highest conversion efficiency, reaching as high as 27%, and have considerable market potential.

[0003] However, most perovskite solar cells currently can only achieve stable conversion efficiency performance in a laboratory glove box. This is mainly because the solar cells need to maintain conversion efficiency for a long time in an environment with low moisture and low oxygen concentration. Therefore, how to effectively encapsulate the perovskite solar cells to avoid being affected by moisture and oxygen in the atmospheric environment is an important issue that needs to be overcome for commercialization.

[0004] Conventional thin-film solar module manufacturing processes typically use laser cutting to pattern the modules. However, laser cutting can easily damage the module's supporting substrate, creating grooves. Furthermore, the cutting path runs straight from one edge of the substrate to the other, creating a channel inside the module that connects to the outside atmosphere. This unevenness of the channel grooves can lead to poor adhesion of the encapsulation material to the substrate, compromising encapsulation quality. Furthermore, it can cause moisture or other gases from the atmosphere to enter the module and come into contact with the module components, impacting their functionality. Summary of the Invention

[0005] Therefore, the purpose of the present invention is to provide a perovskite solar module and a manufacturing method thereof, which can manufacture a perovskite solar module that is suitable for packaging and sealing and has good sealing ability after packaging, effectively preventing water vapor and oxygen in the atmospheric environment from entering the interior of the perovskite solar module, thereby improving the long-term stability of the conversion efficiency of the perovskite solar module.

[0006] The present invention solves the problems of the conventional technology by adopting a technical means to provide a method for manufacturing a perovskite solar module. In the first step, a first substrate is vacuum-coated through a first mask to form a light-transmitting conductive film on the first substrate. The light-transmitting conductive film has a plurality of first grooves extending in parallel and laterally, and the light-transmitting conductive film is divided into a plurality of light-transmitting conductive film blocks. The edges of the light-transmitting conductive film on two sides in the lateral direction are spaced from the edges of the first substrate, so that uncovered areas are formed on the first substrate on two sides in the lateral direction. In the second step, the first substrate on which the light-transmitting conductive film is formed is vacuum-coated through a second mask to form a first carrier transport film on the light-transmitting conductive film. The first carrier transport film has a plurality of first grooves extending in parallel and laterally. A plurality of first spacers are formed to separate the first carrier transport film into a plurality of first carrier transport film blocks, the plurality of first spacers are respectively connected to the plurality of first grooves, and the width of the first spacers is greater than the width of the first grooves; a third step is to vacuum coat the first substrate on which the first carrier transport film is formed through a third mask to form a first precursor layer on the first carrier transport film, and to vacuum evaporate the first substrate on which the first precursor layer is formed through the third mask to generate a second precursor vapor, so that the first precursor layer and the second precursor vapor react to form a perovskite film, the perovskite film having a plurality of second spacers extending in parallel and laterally, to separate the perovskite film into a plurality of perovskite film blocks, Each of the perovskite film blocks has a perovskite film block extension section extending to the first substrate through the first spacer and the first groove, and the plurality of second spacers are respectively connected to the plurality of first spacers; in the fourth step, vacuum coating is performed on the first substrate formed with the perovskite film through the third mask, and a second carrier transport film is formed on the perovskite film, the second carrier transport film having a plurality of third spacers extending in parallel and laterally, and the second carrier transport film is divided into a plurality of second carrier transport film blocks, and the plurality of third spacers are respectively connected to the plurality of second spacers and the plurality of first spacers; in the fifth step, vacuum coating is performed on the first substrate formed with the second carrier transport film through the fourth mask, and a second carrier transport film is formed on the second carrier transport film. A first conductive film is formed, wherein the first conductive film has a plurality of second grooves extending in parallel and laterally, and the first conductive film is divided into a plurality of first conductive film blocks, each of the first conductive film blocks having a first conductive film block extension section extending through the third spacer, the second spacer, and the first spacer to the light-transmitting conductive film, thereby obtaining a perovskite solar cell unit set consisting of a plurality of perovskite solar cell units; a sixth step is to respectively provide second conductive films on both sides of the first substrate in the longitudinal direction, wherein the two second conductive films extend from the two light-transmitting conductive film blocks located on both sides of the first substrate in the longitudinal direction through the edges of the first substrate on both sides in the longitudinal direction to the surface of the first substrate opposite to the surface on which the light-transmitting conductive film blocks are formed;In the seventh step, a packaging film is provided on the perovskite solar cell unit assembly and the second conductive film, with the edges of the packaging film on both sides in the longitudinal direction being attached to the light-transmitting conductive film and the second conductive film, and the edges of the packaging film on both sides in the transverse direction being attached to the uncovered area; and in the eighth step, a second substrate is provided on the packaging film, thereby obtaining a perovskite solar cell module consisting of the second substrate, the packaging film, the second conductive film, and the perovskite solar cell unit assembly.

[0007] In one embodiment of the present invention, a manufacturing method is provided, wherein the light-transmitting conductive film is a metal oxide film or a fluorine-doped metal oxide film.

[0008] In one embodiment of the present invention, a manufacturing method is provided, wherein the first carrier transport film is a nickel oxide film.

[0009] In one embodiment of the present invention, a manufacturing method is provided, wherein the first precursor layer is a lead iodide (PbI2) layer or a tin iodide (SnI2) layer, the second precursor vapor is methylammonium iodide (MAI), formamidinium iodide (FAI), or cesium iodide (CsI), and the perovskite film is a MAPbI3 film, a FAPbI3 film, a CsPbI3 film, a MASnI3 film, a FASnI3 film, or a CsSnI3 film.

[0010] In one embodiment of the present invention, a manufacturing method is provided, wherein the second carrier transport film is a fullerene film or a fullerene derivative film.

[0011] In one embodiment of the present invention, a manufacturing method is provided, wherein the first conductive film is a silver film, a gold film or a copper film.

[0012] In one embodiment of the present invention, a manufacturing method is provided, wherein the second conductive film is a metal tape.

[0013] In one embodiment of the present invention, a manufacturing method is provided, wherein the packaging film material is a polyolefin elastomer or resin.

[0014] In one embodiment of the present invention, a manufacturing method is provided, wherein the first substrate is glass or plastic.

[0015] In one embodiment of the present invention, a manufacturing method is provided, wherein the second substrate is glass or plastic.

[0016] In one embodiment of the present invention, a perovskite solar module manufactured by the above-mentioned manufacturing method is provided.

[0017] The technical means adopted by the manufacturing method of the present invention can manufacture a perovskite solar module that is suitable for packaging and sealing and has good sealing ability after packaging, and can effectively prevent external moisture and oxygen from entering the interior of the perovskite solar module, thereby improving the stability of the perovskite solar module. Simple diagram description

[0018] [Figure 1] is a flow chart showing a method for manufacturing a perovskite solar module according to one embodiment of the present invention; [Figure 2A] is a top view showing an assembly of perovskite solar cell units according to one embodiment of the present invention; [Figure 2B] is a cross-sectional view showing an assembly of perovskite solar cell units in the horizontal direction according to one embodiment of the present invention; [Figure 2C] is a cross-sectional view showing an assembly of perovskite solar cell units in the vertical direction according to one embodiment of the present invention; [Figure 3A] is a cross-sectional view showing a perovskite solar module in the horizontal direction according to one embodiment of the present invention; [Figure 3B] is a cross-sectional view showing a perovskite solar module in the vertical direction according to one embodiment of the present invention. Implementation Method

[0019] The following describes an embodiment of the present invention based on Figures 1 to 3B. This description is not intended to limit the embodiment of the present invention, but is an example of an embodiment of the present invention.

[0020] Figure 1 is a flow chart showing a method 100 for manufacturing a perovskite solar module according to an embodiment of the present invention; Figure 2A is a top view showing a perovskite solar cell unit set B according to an embodiment of the present invention; Figure 2B is a cross-sectional view showing a perovskite solar cell unit set B according to an embodiment of the present invention in the horizontal direction as shown in Figure 2A; Figure 2C is a cross-sectional view showing a perovskite solar cell unit set B according to an embodiment of the present invention in the vertical direction as shown in Figure 2A.

[0021] As shown in Figures 1 to 3B, a method 100 for manufacturing a perovskite solar module according to the present invention includes: a first step S1, vacuum coating a first substrate 10 through a first mask to form a transparent conductive film 1 on the first substrate 10, wherein the transparent conductive film 1 has a plurality of first grooves G1 extending in parallel and laterally, and the transparent conductive film 1 is divided into a plurality of transparent conductive film blocks 1a, and the edges of the transparent conductive film 1 on two lateral sides are spaced from the edges of the first substrate 10, so that uncovered areas 10a are formed on two lateral sides of the first substrate 10; a second step S2, vacuum coating the first substrate 10 formed with the transparent conductive film 1 through a second mask to form a transparent conductive film 1 on the transparent conductive film 1. The first carrier transport film 2 has a plurality of first spacers W1 extending in parallel and laterally, and the first carrier transport film 2 is divided into a plurality of first carrier transport film blocks 2a, the plurality of first spacers W1 are respectively connected to the plurality of first grooves G1, and the width of the first spacers W1 is greater than the width of the first grooves G1; the third step S3, vacuum coating the first substrate 10 formed with the first carrier transport film 2 through a third mask to form a first precursor layer on the first carrier transport film 2, and vacuum evaporating the first substrate 10 formed with the first precursor layer through the third mask to generate a second precursor vapor, so that the first precursor layer and the second precursor vapor react to form a perovskite. The perovskite film 3 is formed by vacuum coating the first substrate 10 with the perovskite film 3 through the third mask, and a second carrier transport film 4 is formed on the perovskite film 3, the second carrier transport film 4 having a plurality of third intervals W3 extending in parallel and laterally, and the second carrier transport film 4 is divided into a plurality of second carrier transport film blocks 4a, each of the perovskite film blocks 3a having a perovskite film block extension section 3b extending to the first substrate 10 through the first interval W1 and the first groove G1, and the plurality of second intervals W2 are respectively connected to the plurality of first intervals W1; the fourth step S4, vacuum coating the first substrate 10 with the perovskite film 3 through the third mask, and forming a second carrier transport film 4 on the perovskite film 3, the second carrier transport film 4 having a plurality of third intervals W3 extending in parallel and laterally, and the second carrier transport film 4 is divided into a plurality of second carrier transport film blocks 4a, The plurality of third spaces W3 are respectively connected to the plurality of second spaces W2 and the plurality of first spaces W1. In a fifth step S5, vacuum coating is performed on the first substrate 10 formed with the second carrier transport film 4 through a fourth mask to form a first conductive film 5 on the second carrier transport film 4. The first conductive film 5 has a plurality of second grooves G2 extending in parallel and laterally, dividing the first conductive film 5 into a plurality of first conductive film blocks 5a. Each of the first conductive film blocks 5a has a first conductive film block extension section 5b extending through the third spaces W3, the second spaces W2, and the first spaces W1 to the light-transmitting conductive film 1, thereby obtaining a perovskite solar cell unit set B consisting of a plurality of perovskite solar cell units Ba.In a sixth step S6, a second conductive film 6 is disposed on each of the longitudinal sides of the first substrate 10. The two second conductive films 6 extend from the two light-transmitting conductive film blocks 1a located on each of the longitudinal sides of the first substrate 10 through the longitudinal edges of the first substrate 10 to the surface of the first substrate 10 opposite to the surface on which the light-transmitting conductive film blocks 1a are formed. In a seventh step S7, an encapsulation film P is disposed on the perovskite solar cell assembly B and the second conductive film 6. The longitudinal edges of the encapsulation film P are attached to the light-transmitting conductive film 1 and the second conductive film 6, and the transverse edges of the encapsulation film P are attached to the uncovered area 10a. In an eighth step S8, a second substrate 11 is disposed on the encapsulation film P, thereby obtaining a perovskite solar module 101 consisting of the second substrate 11, the encapsulation film P, the second conductive film 6, and the perovskite solar cell assembly B.

[0022] By using a method 100 for manufacturing a perovskite solar module according to an embodiment of the present invention, the perovskite solar module 101, which is composed of the second substrate 11, the encapsulation film material P, and the perovskite solar cell unit set B, can avoid the traditional manufacturing method of using laser cutting to create grooves on the carrier substrate, that is, to create a channel between the interior of the perovskite solar module and the external atmospheric environment, resulting in poor packaging tightness after packaging, thereby reducing the long-term stability of the perovskite solar module conversion efficiency.

[0023] According to a manufacturing method 100 according to an embodiment of the present invention, the light-transmitting conductive film 1 is a metal oxide film or a fluorine-doped metal oxide film.

[0024] According to the manufacturing method 100 of one embodiment of the present invention, the first carrier transport film 2 is a nickel oxide film.

[0025] According to a manufacturing method 100 of an embodiment of the present invention, the first precursor layer is a lead iodide (PbI2) layer or a tin iodide (SnI2) layer, the second precursor vapor is methylammonium iodide (MAI), formamidinium iodide (FAI), or cesium iodide (CsI), and the perovskite film 3 is a MAPbI3 film, a FAPbI3 film, a CsPbI3 film, a MASnI3 film, a FASnI3 film, or a CsSnI3 film.

[0026] According to the manufacturing method 100 of one embodiment of the present invention, the second carrier transport film 4 is a fullerene film or a fullerene derivative film.

[0027] According to the manufacturing method 100 of an embodiment of the present invention, the first conductive film 5 is a silver film, a gold film or a copper film.

[0028] According to the manufacturing method 100 of an embodiment of the present invention, the second conductive film 6 is a metal tape.

[0029] Perovskite solar cell units made using the above materials have high conversion capabilities and very high market potential.

[0030] According to the manufacturing method 100 of one embodiment of the present invention, the packaging film material P is a polyolefin elastomer or resin.

[0031] By using polyolefin elastomer and performing a heat treatment at 95°C to 110°C, the perovskite solar cell unit set B can be effectively packaged into a perovskite solar module 101, thereby preventing moisture and oxygen in the atmospheric environment from entering the perovskite solar module 101, thereby maintaining the long-term stability of the perovskite solar module 101.

[0032] According to a manufacturing method 100 according to an embodiment of the present invention, the first substrate 10 is glass or plastic.

[0033] According to the manufacturing method 100 of an embodiment of the present invention, the second substrate 11 is glass or plastic.

[0034] The technical means adopted by the manufacturing method of the present invention can manufacture a perovskite solar module that is suitable for packaging and sealing and has good sealing ability after packaging, effectively preventing external moisture and oxygen from entering the interior of the perovskite solar module, and improving the long-term stability of the perovskite solar module conversion efficiency.

[0035] The above description and explanation are only the description of the preferred embodiment of the present invention. Those with ordinary knowledge in this technology can make other modifications based on the scope of the patent application defined below and the above description. However, these modifications should still be in accordance with the spirit of the invention and within the scope of the rights of the present invention.

[0036] 100: Manufacturing method of perovskite solar module

[0037] 101: Perovskite Solar Module

[0038] 1: Transparent conductive film

[0039] 10: First substrate

[0040] 10a: Uncovered area

[0041] 11: Second substrate

[0042] 1a: Transparent conductive film block

[0043] 2: First carrier transport film

[0044] 2a: First carrier transport film block

[0045] 3: Perovskite film

[0046] 3a: Perovskite film block

[0047] 3b: Perovskite film block extension

[0048] 4: Second carrier transport film

[0049] 4a: Second carrier transport film block

[0050] 5: First conductive film

[0051] 5a: first conductive film block

[0052] 5b: first conductive film block extension

[0053] 6: Second conductive film

[0054] B: Perovskite solar cell unit assembly

[0055] Ba: Perovskite Solar Cell

[0056] G1: First groove

[0057] G2: Second groove

[0058] W1: First interval

[0059] W2: Second interval

[0060] W3: The third interval

[0061] P: Encapsulation film material

[0062] S1: First step

[0063] S2: Second step

[0064] S3: The third step

[0065] S4: Step 4

[0066] S5: The fifth step

[0067] S6: Step 6

[0068] S7: Step 7

[0069] S8: Step 8

Claims

1. A method for manufacturing a perovskite solar module, comprising: a first step of vacuum coating a first substrate through a first mask to form a light-transmitting conductive film on the first substrate, wherein the light-transmitting conductive film has a plurality of first grooves extending in parallel and laterally to divide the light-transmitting conductive film into a plurality of light-transmitting conductive film blocks, and wherein edges of the light-transmitting conductive film on two lateral sides are spaced from edges of the first substrate, thereby forming uncovered areas on two lateral sides of the first substrate; a second step of vacuum coating the first substrate on which the light-transmitting conductive film is formed through a second mask to form a first carrier transport film on the light-transmitting conductive film, wherein the first carrier transport film has a plurality of first gaps extending in parallel and laterally to separate the first carrier transport film from the first substrate; The carrier transport film is divided into a plurality of first carrier transport film blocks, a plurality of the first intervals are respectively connected to a plurality of the first grooves, and the width of the first intervals is greater than the width of the first grooves; in a third step, vacuum coating is performed on the first substrate on which the first carrier transport film is formed through a third mask to form a first precursor layer on the first carrier transport film, and vacuum evaporation is performed on the first substrate on which the first precursor layer is formed through the third mask to generate a second precursor vapor, so that the first precursor layer reacts with the second precursor vapor to form a perovskite film, the perovskite film having a plurality of second intervals extending in parallel and laterally, and the perovskite film is divided into a plurality of perovskite film blocks, each of the perovskite film blocks having a plurality of second intervals extending in parallel and laterally, and ... The first substrate has a perovskite film block extension extending through the first spacer and the first groove, and the plurality of second spacers are respectively connected to the plurality of first spacers; the fourth step is to vacuum coat the first substrate on which the perovskite film is formed through the third mask, and form a second carrier transport film on the perovskite film, the second carrier transport film having a plurality of third spacers extending in parallel and laterally, and the second carrier transport film is divided into a plurality of second carrier transport film blocks, the plurality of third spacers are respectively connected to the plurality of second spacers and the plurality of first spacers; the fifth step is to vacuum coat the first substrate on which the second carrier transport film is formed through the fourth mask, and form a first conductive film on the second carrier transport film. a first conductive film, the first conductive film having a plurality of second grooves extending in parallel and laterally, thereby dividing the first conductive film into a plurality of first conductive film blocks, each of the first conductive film blocks having a first conductive film block extension section extending through the third spacer, the second spacer, and the first spacer to the light-transmitting conductive film, thereby obtaining a perovskite solar cell unit set consisting of a plurality of perovskite solar cell units; a sixth step, providing second conductive films on both sides of the first substrate in the longitudinal direction, respectively, the two second conductive films extending from the two light-transmitting conductive film blocks located on both sides of the first substrate in the longitudinal direction through the edges of the first substrate on both sides in the longitudinal direction to the surface of the first substrate opposite to the surface on which the light-transmitting conductive film blocks are formed;In a seventh step, a packaging film is disposed on the perovskite solar cell assembly and the second conductive film, with the longitudinal edges of the packaging film attached to the light-transmitting conductive film and the second conductive film, and the transverse edges of the packaging film attached to the uncovered area. In an eighth step, a second substrate is disposed on the packaging film, thereby obtaining a perovskite solar cell module consisting of the second substrate, the packaging film, the second conductive film, and the perovskite solar cell assembly.

2. The manufacturing method according to claim 1, wherein the light-transmitting conductive film is a metal oxide film or a fluorine-doped metal oxide film.

3. The manufacturing method according to claim 1, wherein the first carrier transport film is a nickel oxide film.

4. The manufacturing method of claim 1, wherein the first precursor layer is a lead iodide layer or a tin iodide layer, the second precursor vapor is methylammonium iodide, formamidine hydroiodide, or cesium iodide, and the perovskite film is a MAPbI3 film, a FAPbI3 film, a CsPbI3 film, a MASnI3 film, a FASnI3 film, or a CsSnI3 film.

5. The manufacturing method according to claim 1, wherein the second carrier transport film is a fullerene film or a fullerene derivative film.

6. The manufacturing method according to claim 1, wherein the first conductive film is a silver film, a gold film or a copper film.

7. The manufacturing method according to claim 1, wherein the second conductive film is a metal tape.

8. The manufacturing method according to claim 1, wherein the packaging film material is a polyolefin elastomer or resin.

9. The manufacturing method according to claim 1, wherein the first substrate is a glass substrate or a plastic substrate.

10. The manufacturing method according to claim 1, wherein the second substrate is a glass substrate or a plastic substrate.

11. A perovskite solar module manufactured by the manufacturing method according to any one of claims 1 to 10.

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