DSSC Counter Electrode Transfer Method for Flexible Substrates
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Solution Overview
Problem
Existing methods for preparing counter electrodes for dye-sensitized solar cells (DSSCs) require expensive transparent conductive oxide (TCO) electrodes and vacuum processes, leading to inferior photoelectric efficiency when using carbon-based materials, and pose challenges in applying these electrodes to flexible substrates without deteriorating their properties.
Innovation Solution
A method involving the transfer of a porous membrane with carbon-based materials and platinum nano-particles from a high-temperature resistant substrate to various substrates, including flexible ones, using a transfer method that eliminates the need for TCO and vacuum processes, thereby forming a cost-effective and high-efficiency counter electrode.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If platinum catalyst is deposited by sputtering method requiring vacuum process, then catalytic performance is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent extracts the platinum catalyst from the vacuum deposition process and transfers it to the counter electrode using a simple dip-coating method. The platinum is applied as a colloidal suspension that is then calcined to form active platinum particles, eliminating the need for complex vacuum sputtering equipment while maintaining catalytic functionality.
Solution Approach 2:
The patent replaces the mechanical vacuum sputtering system with a chemical/thermal processing approach. Instead of using vacuum machinery to deposit platinum, the invention uses colloidal chemistry to deposit platinum precursors followed by thermal calcination to activate the catalyst, substituting complex mechanical systems with simpler chemical processes.
2Ease of manufacture
If carbon-based material is used instead of platinum, then manufacturing cost is reduced, but photoelectric efficiency deteriorates
Solution Approach 1:
The patent creates a composite counter electrode structure combining carbon-based material and platinum particles. The carbon substrate provides conductivity and structural support while the platinum particles dispersed on the carbon surface provide catalytic activity. This composite approach leverages the advantages of both materials: the low cost and structural benefits of carbon plus the high catalytic efficiency of platinum.
Solution Approach 2:
The patent applies local quality by concentrating platinum particles only at specific locations where catalytic activity is needed on the counter electrode surface, rather than using pure platinum throughout. The carbon-based material provides the bulk structure and conductivity, while platinum is locally distributed to maximize catalytic function while minimizing material cost.
3Stability of the object's composition
If counter electrode is formed directly on flexible plastic substrate at low temperature, then substrate property is preserved, but electrode performance deteriorates
Solution Approach 1:
The patent segments the electrode formation process into two independent stages: first forming the carbon-based counter electrode structure on the flexible substrate at low temperature to preserve substrate integrity, then separately preparing and transferring platinum catalyst particles onto this pre-formed structure. This segmentation allows each component to be optimized independently - the substrate remains flexible while the electrode achieves high performance.
Solution Approach 2:
The patent performs preliminary action by first forming the carbon-based counter electrode structure on the flexible substrate before adding the platinum catalyst. This preliminary structure formation at low temperature preserves the flexible substrate properties, and then the platinum is subsequently introduced to provide the necessary catalytic performance without requiring high-temperature processing of the entire assembly.
4Reliability
If TCO electrode is used in existing methods, then electrode conductivity is improved, but manufacturing cost increases
Solution Approach 1:
The patent replaces expensive transparent conductive oxide (TCO) materials with a cost-effective carbon-based material for the counter electrode. The carbon material provides sufficient conductivity for the counter electrode function at a fraction of the cost of TCO, eliminating the need for expensive rare metal oxides while maintaining electrical performance.
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
This approach results in a counter electrode with superior photoelectric efficiency that can be applied to diverse substrates, including flexible ones, without the need for expensive TCO or vacuum processes, enhancing the suitability for flexible electronics like wearable devices.
Implementation Method 1
A method involving the transfer of a porous membrane with carbon-based materials and platinum nano-particles from a high-temperature resistant substrate to various substrates, including flexible ones, using a transfer method
Implementation Method 2
a counter electrode which catalyses by platinum (Pt)
Implementation Method 3
a porous membrane including carbon-based material and platinum nano-particles
Data Source
AI summary
The present invention relates to a counter electrode for DSSC which includes a porous membrane include a carbon-based material calcinated at high temperature and a platinum nano-particles and maintains higher conductivity than a thin membrane and in which the electrolyte moves smoothly, a method of preparing the same, and a DSSC using the same which is improved in photoelectric efficiency.