Dye-Sensitized Solar Cell Module Side-Connection Design
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Solution Overview
Problem
Conventional dye-sensitized solar cell modules face limitations in panel performance and efficiency due to the large area occupied by externally protruding electrode portions, which are fragile and restrict design, leading to marketability issues and electrolyte leakage, and the electrolyte injection port requires additional processing steps increasing manufacturing costs and safety concerns.
Innovation Solution
The solution involves forming connection parts at the side surfaces of the transparent conductive substrates for the working and counter electrodes, allowing modules to be bonded without externally protruding electrode portions, and repositioning the electrolyte injection port to improve safety and design, enabling increased effective cell area and simplified module assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If externally protruding electrode portions are used for module connection, then electrical connection between modules is achieved, but the effective cell area is reduced and the electrodes are fragile and prone to breakage
Solution Approach 1:
The patent moves the electrode connection interface from the front surface (2D plane) to the side surface (3D dimension) of the module. Connection parts are formed at the side surfaces of the transparent conductive substrates, allowing electrical connection between adjacent modules without sacrificing front surface area. This dimensional transition eliminates the need for externally protruding electrodes while maximizing the effective cell area.
2Ease of manufacture
If externally protruding electrode portions are used, then module assembly is simplified, but the design is restricted and marketability is reduced due to fragility
Solution Approach 1:
By relocating connection parts to the side surfaces, the patent achieves both simplified assembly and improved design flexibility. The side-surface connections are inherently more robust than protruding electrodes, eliminating fragility concerns while maintaining ease of assembly through direct side-to-side bonding of adjacent modules.
3Ease of manufacture
If electrolyte injection port is formed with additional processing steps, then electrolyte injection is enabled, but manufacturing cost increases and safety concerns arise
Solution Approach 1:
The patent incorporates the electrolyte injection function into the sealant application process itself. The sealant is applied in a specific pattern that automatically forms both the sealing structure and the electrolyte injection port, eliminating the need for separate injection port formation steps and reducing manufacturing complexity while maintaining safety.
Solution Approach 2:
The patent combines multiple functions into the sealant application process: sealing the module edges, providing structural bonding, and creating the electrolyte injection port. This merging of functions eliminates additional processing steps and reduces manufacturing cost while maintaining safety through the integrated design.
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 enhances panel performance and efficiency by maximizing the effective cell area, reduces the risk of electrode breakage, improves marketability, and simplifies the manufacturing process by eliminating the need for sealing glass and reducing electrolyte leakage.
Implementation Method 1
This photoelectric conversion mechanism is configured to absorb visible light from a Ru-based pigment adsorbed by a TiO2 electrode and then formed into a photocurrent.
Data Source
AI summary
Disclosed is a dye-sensitized solar cell module and a method of manufacturing the same. More specifically a counter electrode has connection parts formed within the side surfaces of the transparent conductive substrates. Edges of the working electrode and the counter electrode are bonded with each other by a sealant along the outer peripheral except for at one or more portions of the edges to form an electrolyte injection port. An electrolyte is then injected through the electrolyte injection hole into a space between the working electrode and the counter electrode. The electrolyte injection hole is then sealed by a sealant.