Organic Solar Cell Module Staggered Electrode Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing organic solar cell modules are limited by the width of the stripe pattern and the number of sub cells, leading to restricted voltage magnitude and inefficient manufacturing processes due to the limitations of coating technologies, which result in a final module size determined by the width of solar cell sub cells and the number of sub cells in a predetermined area.
Innovation Solution
A manufacturing method involving the etching of first electrode materials in a staggered pattern to form sub cell lower electrodes, followed by coating a buffer layer and photoactive layer in a stripe pattern, and corresponding second electrode materials to increase the number of sub cells and reduce manufacturing costs by using a strip-type patterning process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the width of stripe pattern and number of sub cells are increased to improve voltage magnitude, then the module size is determined by coating technology limits, but the number of sub cells in a predetermined area is limited
Solution Approach 1:
The lower electrode is divided into multiple separate electrode regions arranged in a staggered pattern, with each region corresponding to one sub cell. This segmentation allows multiple sub cells to be arranged in a predetermined area without being limited by traditional stripe pattern width constraints, thereby increasing the number of sub cells and voltage magnitude.
Solution Approach 2:
The electrode pattern transitions from a simple linear stripe arrangement to a two-dimensional staggered grid arrangement. This dimensional change enables more efficient space utilization, allowing more sub cells to be packed into the same area while maintaining proper electrode spacing and alignment.
2Ease of manufacture
If traditional slot die coating method is used to coat buffer layer and photoactive layer, then coating process is simple, but lower and upper electrodes must be stacked in stripe pattern which limits sub cell configuration
Solution Approach 1:
The lower electrode is segmented into multiple independent electrode regions arranged in a staggered pattern rather than a continuous stripe. This segmentation allows the electrode layout to accommodate more sub cells in a predetermined area while still using the simple slot die coating process for applying the buffer and photoactive layers.
3Power
If more sub cells are arranged in a predetermined area to increase voltage, then the photoactive area of each sub cell is reduced, but the total manufacturing cost increases
Solution Approach 1:
By arranging electrodes in a staggered two-dimensional pattern rather than simple linear stripes, the design maximizes the number of sub cells that can fit in a given area. This efficient spatial arrangement increases voltage output without requiring additional manufacturing resources or increasing costs.
Solution Approach 2:
The staggered electrode pattern allows for more effective utilization of the substrate area, combining multiple sub cells in a compact arrangement. This merging of space utilization efficiency with increased sub cell count achieves higher voltage without proportionally increasing manufacturing costs.
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 allows for the creation of organic solar cell modules with twice or more sub cells in the same area, increasing operating voltage and reducing manufacturing costs, while enhancing fill factor, open-circuit voltage, and power conversion efficiency.
Implementation Method 1
coating a buffer layer and a photoactive layer on the lower electrode etched in a staggered pattern using a slot die coating apparatus
Data Source
AI summary
The present invention relates to a manufacturing method of an organic solar cell module and an organic solar cell module, and more particularly, to an organic solar cell module and a manufacturing method thereof, in which lower electrodes are spaced and etched in a staggered pattern and upper electrodes are coated to correspond to the lower electrodes to reduce a photoactive area of a sub cell and arrange more sub cells than sub cells in the related art in a predetermined area. Further, the present invention relates to an organic solar cell module and a manufacturing method thereof, which can reduce the installation cost and the manufacturing cost by coating a buffer layer and a photoactive layer on the lower electrode etched in the staggered pattern using a slot die coating apparatus in the related art.