Dye-Sensitized Solar Cell Segmentation and Counter Electrode Stability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Dye-sensitized solar cells face challenges in scaling up due to electrolyte injection issues between glass substrates, leading to voltage drops and decreased photoelectric conversion efficiency, and the formation of catalyst layers with low film strength causes stripping problems, affecting the production of large-area solar cells.
Innovation Solution
A dye-sensitized solar cell design with a stable counter electrode conductive layer and catalyst layer formed on a porous insulation layer, where the counter electrode conductive layer is created through vapor deposition with controlled pore formation to prevent stripping, and a method for producing solar cells and modules with a specific lamination order and carrier transport material injection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If the electrolyte solution is injected between opposed glass substrates with transparent conductive films, then a small-area solar cell can be prototyped, but increasing the solar cell area increases the voltage drop in the transparent conductive film, which increases the inner series resistance and decreases the photoelectric conversion efficiency
Solution Approach 1:
The solar cell is divided into multiple small-area cells arranged in series on a single glass substrate. Each small cell has its own transparent conductive film electrode, and the cells are connected in series through contact between the conductive film of one cell and the counter electrode of the adjacent cell. This segmentation allows each cell to maintain low series resistance while the overall module achieves large area and higher voltage through series connection.
Solution Approach 2:
The patent transitions from a single large-area cell configuration to a multi-cell array configuration on the same substrate area. By arranging multiple small cells in series across the substrate surface, the system achieves both large effective area and low series resistance per cell, resolving the contradiction between area scaling and efficiency maintenance.
2Ease of manufacture
If the catalyst layer is formed on the porous insulation layer by vapor deposition, then the counter electrode can be created, but if the catalyst layer particles have low film strength, the film is stripped when the counter electrode conductive layer is formed thereon, making solar cell production impossible
Solution Approach 1:
The porous insulation layer is formed first to provide a mechanically robust foundation before the catalyst layer is deposited. This preliminary structural layer prevents the weak catalyst film from stripping during subsequent processing steps, while still allowing the catalyst to function effectively for the counter electrode.
3Reliability
If a porous semiconductor layer with fine particles is used to prevent catalyst layer particles from passing through, then internal short-circuit is avoided, but the particle size control degrades performance because the particle size of porous semiconductor layer significantly affects performance
Solution Approach 1:
The porous insulation layer serves as an intermediary barrier between the porous semiconductor layer and the catalyst layer. Instead of relying solely on particle size matching to prevent short-circuits, the insulation layer acts as a physical mediator that blocks catalyst particles while maintaining the performance-optimized particle size of the semiconductor layer.
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 design enhances the photoelectric conversion efficiency and stability of the solar cells, allowing for successful production of large-area solar cells and modules with improved series connections between adjacent cells.
Implementation Method 1
the counter electrode conductive layer is formed by vapor deposition
Implementation Method 2
a photoelectric conversion layer made of a photoelectric conversion material with a light sensitizing dye adsorbed therein to provide an absorption spectrum in a visible light region
Data Source
AI summary
Provided are a dye-sensitized solar cell wherein a counter electrode composed of a stable counter electrode conductive layer and a catalyst layer is formed on a porous insulation layer, and a dye-sensitized solar cell module wherein the dye-sensitized solar cell is utilized. A dye-sensitized solar cell includes a supporting body made of a light-transmissive material, and a laminate wherein a conductive layer, a photoelectric conversion layer having a porous semiconductor layer with a dye adsorbed therein, a porous insulation layer, a counter electrode conductive layer, and a catalyst layer are laminated in the order presented. The photoelectric conversion layer and the porous insulation lay are filled with a carrier transport material.