Laminated Solar Cell Module Pinhole Reduction
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Solution Overview
Problem
The existing printed solar cells and solar cell modules based on semi-conducting organic molecules face a high risk of pinhole formation during the printing process, leading to short circuits and reduced efficiency, especially in low light conditions.
Innovation Solution
A method for producing laminated solar cell modules using flexible substrates with spatially separated electrodes and an organic active layer, where the active layers are brought into physical contact through heat and pressure in a roll-to-roll process without an adhesive layer, reducing the risk of pinholes and short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If organic active layer is printed using roll-to-roll process, then production efficiency and area coverage are improved, but pinhole formation increases leading to short circuits
Solution Approach 1:
The solar cell module is divided into multiple substrate portions, each containing a portion of the organic active layer. This segmentation allows for controlled lamination of multiple layers, where the combined thickness of the segmented active layers reduces pinhole formation while maintaining high production efficiency through roll-to-roll processing
Solution Approach 2:
The electrodes and organic active layer are prepared on separate substrate portions before lamination. This preliminary preparation allows the active layer to be deposited with controlled thickness and uniformity, reducing pinhole formation while maintaining efficient roll-to-roll production
2Strength
If adhesive layer is added to laminate substrates, then bonding strength is improved, but pinhole formation and short circuit risk increase
Solution Approach 1:
The adhesive layer is completely removed from the lamination process. Instead, the organic active layer itself serves as the bonding medium between substrate portions, eliminating the source of pinhole formation while maintaining adequate bonding strength for the solar cell module
Solution Approach 2:
The organic active layer acts as an intermediary substance that provides both bonding function and electrical functionality. This eliminates the need for separate adhesive layers that would introduce pinholes, while the active layer's inherent properties provide sufficient adhesion between substrate portions
3Reliability
If active layer thickness is increased to reduce pinholes, then short circuit risk is reduced, but manufacturing complexity and energy consumption increase
Solution Approach 1:
Instead of depositing a single thick active layer that would require high energy input, the active layer is segmented into multiple thinner layers deposited on separate substrate portions. The combined thickness achieves the same pinhole reduction effect, but each individual deposition step requires less energy, reducing overall process energy consumption
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 method enhances the efficiency of solar cell modules by minimizing short circuits, making them suitable for low light conditions and reducing the need for post-processing steps, while allowing for larger active areas and more efficient energy harvesting.
Implementation Method 1
laminating by means of heat and pressure said first and said second substrate portions together in a roll-to-roll process
Data Source
AI summary
The present invention relates to a method for laminating solar cell modules comprising a plurality of solar cells electrically connected in series. The method comprises: providing a first and a second flexible substrate portion suitable for roll-to-roll deposition; providing a plurality of first electronic conductors on said first substrate portion and a plurality of second electrodes on said second substrate portion, wherein said plurality of first and second electrodes are provided as stripes spatially separated such that a plurality of gaps is formed; depositing an electronic conductor on one end of the first and second electrodes and depositing a continuous or discontinuous active layer on said plurality of first electrodes or said plurality of second electrodes, wherein said continuous or discontinuous active layer is an organic active layer; laminating by means of heat and pressure said first and said second substrate portions together in a roll-to-roll process such that the electronic conductors are brought into physical contact with the respective electronic conductor arranged on the opposite substrate, and that the active layer is brought into physical contact with the other one of said plurality first electrodes or said plurality of second electrodes and such that the active layer is brought into electrical contact with said plurality of first electrodes and said plurality of second electrodes. The plurality of first electrodes is arranged off-set relative said plurality of second electrodes such that each of said plurality of gaps between said plurality of second electrodes are partly or fully covered at least in one direction by respective one of said plurality of first electrodes. The present invention also relates to a solar cell module.