Flexible Photoelectric Electrode Patterning Without Barrier Damage
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Solution Overview
Problem
Existing methods for patterning electrodes on flexible photoelectric conversion elements, such as solar cells, result in non-uniform appearances and reduce the durability of the element due to damage to the gas barrier layer when using laser scribing.
Innovation Solution
A manufacturing method involving the use of a pulsed laser with a pulse width of less than 1 ns to form through holes in the electrode layer, ensuring a line width of less than 100 μm and a ratio of minimum to average line width of 0.57 to 0.91, which minimizes damage to the gas barrier layer and maintains its integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser scribing is used to pattern electrodes on flexible photoelectric conversion elements, then electrode patterning is achieved, but the gas barrier layer is damaged resulting in non-uniform appearance and reduced durability
Solution Approach 1:
The patent changes the key parameter of laser pulse width from conventional values (typically nanosecond range) to ultrashort pulse width (picosecond or femtosecond range, less than 1 ns). This parameter change enables precise electrode removal through ablation without transmitting excessive heat to the gas barrier layer, thereby maintaining barrier integrity while achieving accurate electrode patterning.
Solution Approach 2:
The patent replaces conventional mechanical or thermal patterning methods with ultrashort pulsed laser ablation. This substitution allows for contactless, precise material removal with minimal thermal diffusion, avoiding the damage that occurs with traditional laser scribing or mechanical patterning methods.
2Ease of manufacture
If conventional laser scribing is used for electrode patterning, then electrode formation is achieved, but the appearance uniformity is compromised
Solution Approach 1:
By changing the laser pulse width parameter to ultrashort durations (less than 1 ns), the patent achieves clean ablation of the electrode layer with minimal collateral damage. This produces sharp, well-defined edges and maintains the uniform appearance of surrounding areas, solving the appearance uniformity problem while keeping the manufacturing process straightforward.
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 method achieves a flexible photoelectric conversion element with high durability and a uniform appearance by reducing gas intrusion, particularly water vapor, while preserving the gas barrier property.
Implementation Method 1
removing a part of the first electrode layer using a pulsed laser to form a through hole penetrating the first electrode layer and including a plurality of holes partially overlapping each other
Data Source
AI summary
A photoelectric conversion element manufacturing method according to the present disclosure includes: (A) forming a first electrode layer on a gas barrier layer; (B) removing a part of the first electrode layer using a pulsed laser to form a through hole penetrating the first electrode layer and including a plurality of holes partially overlapping each other; (C) forming a light absorbing layer on the first electrode layer and on the gas barrier layer exposed by the through hole; and (D) forming a second electrode layer on the light absorbing layer.