Clad Metal Substrate for Dye-Sensitized Solar Cells
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Solution Overview
Problem
Dye-sensitized solar cells face reduced power generation efficiency due to high electrical resistance in metal substrates made of titanium, titanium alloys, or stainless steel, which also suffer from corrosion issues with electrolytes.
Innovation Solution
A metal substrate with a clad material structure, comprising a nonporous first metal layer (e.g., titanium) for corrosion resistance and a second metal layer (e.g., copper or aluminum) with lower electrical resistance, bonded together to reduce electrical resistance and maintain corrosion protection, optionally with a third metal layer for thermal expansion matching and additional corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal substrate made of titanium, titanium alloy, or stainless steel is used, then corrosion resistance against the electrolyte is improved, but electrical resistance increases causing electrical loss
Solution Approach 1:
The invention uses a composite metal substrate structure consisting of a first metal layer (titanium, titanium alloy, or stainless steel) providing corrosion resistance and a second metal layer (copper, aluminum, or their alloys) providing low electrical resistance. This composite structure resolves the contradiction by combining materials with complementary properties, allowing the substrate to simultaneously resist corrosion and conduct electricity efficiently.
2Reliability
If only a first metal layer made of titanium or its alloy is used, then corrosion resistance is maintained, but electrical resistance remains high reducing power generation efficiency
Solution Approach 1:
The composite structure combines a corrosion-resistant first metal layer with a highly conductive second metal layer, resolving the contradiction between reliability and productivity. The second metal layer's low electrical resistance reduces electrical loss and improves power generation efficiency, while the first metal layer maintains corrosion resistance against the electrolyte.
3Productivity
If a second metal layer with lower electrical resistance is added to reduce electrical loss, then power generation efficiency improves, but device complexity increases
Solution Approach 1:
The invention implements a two-layer composite metal substrate structure where each layer serves a specific function. The first metal layer provides corrosion resistance while the second metal layer provides electrical conductivity. This structured composite approach improves power generation efficiency while maintaining manageable device complexity through clear functional division.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively reduces electrical resistance in the metal substrate, enhancing power generation efficiency while maintaining corrosion resistance against the electrolyte, and preventing defects such as breakage and thermal deformation.
Implementation Method 1
a second metal layer made of a metal having lower electrical resistance than the first metal layer and bonded to a side of the first metal layer opposite to the dye-sensitized solar cell element
Implementation Method 2
a nonporous first metal layer, arranged on an anode side of a dye-sensitized solar cell element, made of a metal having corrosion resistance against an electrolyte of the dye-sensitized solar cell element
Data Source
AI summary
This metal substrate for a dye-sensitized solar cell includes a clad material including a nonporous first metal layer, arranged on an anode side of a dye-sensitized solar cell element, made of a metal having corrosion resistance against an electrolyte of the dye-sensitized solar cell element and a second metal layer made of a metal having lower electrical resistance than the first metal layer and bonded to a side of the first metal layer opposite to the dye-sensitized solar cell element.