Photoelectric Conversion Panel Venting to Prevent Film Separation
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Solution Overview
Problem
In the manufacturing of photoelectric conversion panels, the inorganic insulating film tends to separate from the organic film due to gas generation during the heating process, leading to deformation and changes in electric properties of the elements, especially with thicker photoelectric conversion elements causing stress on the substrate.
Innovation Solution
A photoelectric conversion panel design that includes a thin film transistor, a first organic film, a photoelectric conversion element, and a first inorganic insulating film with through holes to expose parts of the organic film, allowing gas generated during the heating process to escape through these holes, preventing the inorganic insulating film from separating from the organic film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a heating step is carried out in the manufacturing process, then the organic film is cured or dried, but gas is generated from the organic film which pushes up the inorganic insulating film, causing separation
Solution Approach 1:
Through holes are formed in the inorganic insulating film before the heating step. This preliminary action creates escape paths for gas that will be generated during subsequent heating, preventing the gas from accumulating and pushing up the film to cause separation.
Solution Approach 2:
The gas generated during heating, which is normally a harmful factor causing film separation, is converted into a beneficial effect by providing controlled escape paths through the through holes. The gas is directed to exit through specific openings rather than accumulating underneath the film, thus preventing adhesion failure.
2Reliability
If photoelectric conversion elements with larger thickness are used, then photoelectric conversion performance is improved, but stress occurs on the substrate making the inorganic insulating film more prone to separation
Solution Approach 1:
Through holes are formed in the inorganic insulating film before the photoelectric conversion elements are formed and before heating steps occur. This preliminary preparation of escape paths ensures that when stress and gas generation occur during subsequent processing, the gas can escape through the pre-formed holes, preventing separation even with thick photoelectric conversion elements present.
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 configuration effectively prevents the inorganic insulating film from separating from the organic film, maintaining the integrity and electrical properties of the photoelectric conversion panel elements, even under thermal stress, thereby ensuring the stability and performance of the panel.
Implementation Method 1
In a case where heat generated in the heating step is transmitted to the first organic film after the inorganic insulating film is formed is heated, gas is generated in some cases from the first organic film
Data Source
AI summary
A photoelectric conversion panel includes: a thin film transistor; a first organic film formed in an upper layer with respect to the thin film transistor; a photoelectric conversion element formed in an upper layer with respect to the first organic film; and a first inorganic insulating film formed so as to cover at least a part of the first organic film, wherein the first inorganic insulating film has a through hole that exposes a part of the first organic film.