Perovskite Solar Cell Defect Removal via Counter Electrode Cavity
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Solution Overview
Problem
Perovskite solar cells suffer from defects such as pinholes caused by the close proximity of transparent and counter electrodes, leading to short circuits and impaired electric properties, which are difficult to completely prevent during the manufacturing process, especially when using flexible substrates like polymer films or ultra-thin glass.
Innovation Solution
A photoelectric conversion device with a laminate structure featuring a cavity on the counter electrode-side that penetrates through the counter electrode and has a larger opening area than the active layer, along with a method for defect treatment involving an adhesive or suction process to remove defects and their peripheral parts, using a defect-position determining unit and defect-removing unit to improve device efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a flexible substrate like polymer film is used, then the solar cell can be installed on curved or poor load-bearing roofs and weight is reduced, but the substrate has lower heat and chemical resistance and higher thermal expansion coefficient compared to glass
Solution Approach 1:
The patent applies local quality by creating a cavity structure at specific defect locations rather than changing the entire substrate material. The cavity is formed locally at pinhole positions to separate electrodes, maintaining the flexibility and light weight of polymer substrates while providing localized structural modification where needed.
2Manufacturing precision
If the perovskite layer is made thin to allow light transmission, then the layer can be formed by wet-coating process, but defects such as pinholes are more likely to form where electrodes are locally close
Solution Approach 1:
The patent extracts or removes the problematic region by forming a cavity at the defect location that penetrates through the counter electrode. This removes the short-circuit path caused by pinholes where the perovskite layer is too thin, while preserving the thin-layer structure and wet-coating manufacturing process for the majority of the device.
Solution Approach 2:
The patent introduces a vertical dimension by forming a cavity that penetrates through the counter electrode layer. This creates a three-dimensional structural modification at defect locations, adding depth to the electrode separation strategy beyond just lateral positioning.
3Manufacturing precision
If adhesive material is pressed against the defect to remove it, then the defect and peripheral part can be removed, but the adhesive material must be applied precisely at the defect position
Solution Approach 1:
The patent employs a suction mechanism that automatically draws adhesive material to the defect location through negative pressure. The system self-regulates by allowing the adhesive to be pulled precisely to where it is needed (at the defect) without requiring complex positioning control, simplifying the overall application process.
Data Source
AI summary
A method for manufacturing a photoelectric conversion device, that includes: forming a laminate structure of a substrate, a transparent electrode, an active layer produced by wet-coating, and a counter electrode, stacked in this order; and thereafter forming a cavity by: (a) pressing an adhesive material just against a defect formed on the surface of said counter electrode, and then peeling off said adhesive material together with said defect and the peripheral part thereof; or (b) sucking a defect formed on the surface of said counter electrode, so as to remove said defect and the peripheral part thereof, where said cavity penetrates through the counter electrode and unreached to the transparent electrode.