Collecting Electrode Thickening to Prevent Peeling in Photoelectric Elements
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Solution Overview
Problem
The peeling of layers and wiring in photoelectric conversion elements due to force applied to the collecting electrode can lead to a decrease in photoelectric conversion efficiency or loss of function, necessitating a solution to enhance the strength and manufacturing method of these elements.
Innovation Solution
A photoelectric conversion element with a collecting electrode thickness of at least 4 μm at the joint portion between the electrode and conductor, along with a manufacturing process involving the formation of a photoelectric conversion layer, electrode layers, and conductor joining, is developed to improve structural integrity and prevent peeling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the collecting electrode thickness is increased to prevent peeling, then the strength and reliability improve, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent applies local quality by increasing the collecting electrode thickness specifically at the joint portion where the conductor is attached, rather than uniformly increasing the entire electrode thickness. This localized thickening (to 4 μm or more at the joint portion) provides enhanced strength exactly where the peeling force is applied, while maintaining thinner dimensions in other areas to reduce overall material usage and manufacturing complexity.
2Reliability
If the collecting electrode thickness is increased to prevent peeling, then the reliability improves, but the material consumption increases
Solution Approach 1:
The patent implements local quality by concentrating the increased material thickness (4 μm or more) specifically at the joint portion between the collecting electrode and conductor, where it is most needed to prevent peeling. The rest of the collecting electrode can maintain a thinner profile, thereby improving reliability at the critical joint area while minimizing overall material consumption.
3Ease of manufacture
If a thin collecting electrode is used, then the manufacturing ease and material usage improve, but the peeling resistance deteriorates
Solution Approach 1:
The patent resolves this contradiction by applying local quality - the collecting electrode maintains a thin profile for most of its area to ensure ease of manufacture and reduce material usage, but features a localized thickened region (4 μm or more) at the joint portion where the conductor is attached. This localized reinforcement provides the necessary peeling resistance exactly where the mechanical stress is concentrated, during the joining process and thereafter.
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 increased thickness of the collecting electrode significantly enhances the tensile strength of the photoelectric conversion element, reducing the likelihood of peeling and maintaining efficiency even with layers having cleavability, thus addressing the issue of strength and manufacturing.
Implementation Method 1
A photoelectric conversion element that converts light energy into electric energy
Data Source
AI summary
Provided is a photoelectric conversion element capable of suppressing a decrease in strength. A photoelectric conversion element comprises: a photoelectric conversion layer (26); an electrode layer (24) adjacent to the photoelectric conversion layer; a collecting electrode (30) adjacent to the electrode layer; and a conductor (50) joined to the collecting electrode. The thickness of the collecting electrode (30) at least at a joint portion between the collecting electrode (30) and the conductor (50) is 4 μm or more.