Photoelectric Conversion Element With Varying Photoactive Layer Thickness
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Solution Overview
Problem
Conventional photoelectric conversion elements face inefficiencies due to non-contributory regions at the end portions of substrates during manufacturing, which hinder the increase of the photoelectric conversion area and lead to short circuits during the cutting process, affecting power conversion efficiency and manufacturing yields.
Innovation Solution
A photoelectric conversion element design featuring a substrate with a first electrode extending to the end, a photoactive layer with distinct thickness regions, and a second electrode, where the photoactive layer's second region is thicker to prevent short circuits and utilize the entire substrate as a conversion region, combined with a manufacturing method that forms these layers using a meniscus coating technique to control thickness and prevent electrode short-circuiting during cutting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the size of the photoelectric conversion element is increased to enlarge the photoelectric conversion region, then the power conversion efficiency is improved, but the manufacturing cost and complexity increase
Solution Approach 1:
The photoactive layer is designed with different thicknesses in different regions: a first thickness in the main photoelectric conversion region and a second thickness (greater than the first) in the end region. This local quality variation ensures adequate photoelectric conversion throughout the entire substrate area while maintaining manufacturing feasibility, thereby improving power conversion efficiency without proportionally increasing manufacturing complexity
2Area of stationary object
If the substrate size is increased to maximize the photoelectric conversion area, then the useful conversion region is improved, but non-contributory regions at the end portions are generated due to manufacturing process limitations
Solution Approach 1:
The patent applies local quality by creating a photoactive layer with spatially varying thickness. The end region has a greater thickness than the main region, which compensates for the previously non-contributory nature of end portions. This ensures that the entire substrate area, including end portions, contributes to photoelectric conversion, thereby increasing the effective conversion area while maintaining manufacturing reliability
Solution Approach 2:
The manufacturing method forms the photoactive layer with a predetermined thickness profile before the cutting process. By preliminarily establishing the thicker end region, the patent ensures that subsequent cutting operations will not create short circuits or defective regions, thereby maintaining high manufacturing yield while maximizing the photoelectric conversion area
3Reliability
If the photoactive layer thickness is increased in the end region to prevent short circuits, then the reliability is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The patent implements parameter changes by varying the thickness parameter of the photoactive layer across different spatial regions. The end region is designed with a greater thickness parameter than the main region, which provides a safety margin against short circuits during cutting. This parameter variation is achieved through controlled deposition or coating processes that can accommodate the thickness gradient without requiring extreme manufacturing precision
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
Enhances power conversion efficiency and manufacturing yields by preventing short circuits and optimizing the photoelectric conversion region, allowing for high-yield production of photoelectric conversion elements with improved performance.
Implementation Method 1
a photoelectric conversion layer provided above the first electrode... a photoelectric conversion element such as an organic photovoltaics using an organic semiconductor
Implementation Method 2
a manufacturing method that forms these layers using a meniscus coating technique to control thickness
Data Source
AI summary
A photoelectric conversion element includes: a substrate having an element formation surface; a first electrode provided on the element formation surface and extending along one direction of the element formation surface up to an end portion of the element formation surface; a photoelectric conversion layer provided above the first electrode and including a first region having a first thickness and a second region extending from an end portion of the first region up to an end portion of the first electrode and having a second thickness larger than the first thickness; and a second electrode provided above the first and second regions and extending up to an end portion of the photoelectric conversion layer.