Photoelectric Conversion Panel With Through-Hole Inorganic Layer
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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 heat-generated gases, leading to deformation and changes in electric properties, especially when thicker photoelectric conversion elements are present, causing stress on the substrate.
Innovation Solution
A photoelectric conversion panel design that includes a first inorganic layer with a through hole connecting the first and second organic films, allowing gas generated during the heating process to escape, thereby preventing the inorganic insulating film from separating from the organic film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a second organic film is formed by performing a heating process after the first organic film is formed, then the second organic film can be properly formed and cured, but gas is generated from the first organic film which pushes up the inorganic insulating film, causing separation and loosening
Solution Approach 1:
The inorganic insulating film is segmented by forming through-holes that divide it into regions, allowing gas to escape through these openings. This segmentation prevents the film from being pushed up uniformly, maintaining its structural integrity while accommodating gas generation during heating.
Solution Approach 2:
The through-holes in the inorganic insulating film act as intermediaries that provide a designated pathway for gas to escape. Instead of the gas forcing its way through the film and causing separation, the holes serve as controlled exit points, mediating between the gas generation source and the external environment.
2Reliability
If photoelectric conversion elements are made thicker to improve conversion performance, then photoelectric conversion efficiency is enhanced, but stress occurs on the substrate which makes the inorganic insulating film particularly prone to separating
Solution Approach 1:
The through-holes segment the inorganic insulating film structure, creating localized regions that can accommodate stress from thick photoelectric conversion elements. This segmentation prevents stress from accumulating and causing uniform separation, allowing the film to remain stable despite the additional substrate stress.
Solution Approach 2:
The through-holes are formed in advance before the heating process and subsequent gas generation. These pre-formed openings act as cushioning features that anticipate and accommodate the stress and gas pressure that will arise from thick photoelectric conversion elements, preventing separation before it can occur.
3Reliability
If the inorganic insulating film is formed to cover the first organic film completely, then insulation performance is improved, but the film becomes more prone to separation when heated due to trapped gas
Solution Approach 1:
The inorganic insulating film is segmented with through-holes that maintain its overall coverage and insulation function while creating escape paths for gas. The film remains continuous in most regions, preserving insulation performance, while the segmented holes prevent gas trapping that would cause delamination.
Solution Approach 2:
Gas is extracted from the system through the through-holes in the inorganic insulating film. By providing these extraction pathways, the harmful gas that would otherwise be trapped and cause adhesion failure is removed, allowing the film to maintain both its insulation performance and stable adhesion to the first organic film.
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 restrains the inorganic insulating film from separating from the organic film, maintaining the integrity and performance of the photoelectric conversion panel even with the inclusion of both organic films.
Implementation Method 1
heat generated in the heating process is transmitted via the inorganic insulating film to the first organic film. Therefore, when the first organic film already 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; a first inorganic layer formed so as to cover at least a part of the photoelectric conversion element, and to cover the first organic film; and a second organic film formed in an upper layer with respect to the first organic film, wherein the first inorganic layer is provided with a first through hole connecting the first organic film and the second organic film.