Photovoltaic Devices With 3D Surface Features
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Solution Overview
Problem
Conventional thin film solar cells have low photoelectric conversion efficiency due to limited light utilization, primarily because the light path through the photovoltaic layer is restricted by its thickness, leading to inefficiency and high material costs, which hinder their widespread adoption.
Innovation Solution
The development of photovoltaic cells with three-dimensional optical architectures, featuring light transmissive layers with surface patterns that scatter light, increasing its path through the photovoltaically-active layer, thereby enhancing light absorption and reducing material thickness, which includes a transparent electrode layer, a photovoltaically-active layer, and a reflective second electrode, manufactured using methods like chemical vapor deposition and embossing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the photovoltaic layer is made thinner to reduce material costs, then material costs decrease, but light absorption efficiency deteriorates
Solution Approach 1:
The patent introduces three-dimensional surface features (microposts, pyramids, or irregular patterns) on the light transmissive layer to add vertical and lateral dimensionality to an otherwise planar structure. This dimensional change creates multiple light reflection paths and increases the effective optical path length without increasing the physical thickness of the photovoltaic layer, thereby maintaining thin profile while improving light absorption efficiency
Solution Approach 2:
The light transmissive layer with three-dimensional surface features acts as an intermediary between incident light and the photovoltaic layer. This intermediary structure scatters and redirects light multiple times before it reaches the photovoltaic layer, increasing the probability of photon absorption without requiring a thicker active layer
2Loss of energy
If the photovoltaic layer thickness is increased to improve light absorption, then light absorption efficiency improves, but device flexibility and weight increase
Solution Approach 1:
By creating three-dimensional surface features on the light transmissive layer, the patent effectively increases the optical path length in the vertical dimension without increasing the physical thickness of the photovoltaic layer in the lateral dimension, thus improving light absorption while maintaining device flexibility and low weight
3Ease of manufacture
If conventional flat surface structures are used, then manufacturing is simple, but light utilization efficiency is low
Solution Approach 1:
The patent modifies the surface morphology parameters of the light transmissive layer by introducing three-dimensional features with controlled dimensions (post heights of 1-100 micrometers, varying diameters and spacing). These parameter changes enhance light scattering and trapping effects while maintaining compatibility with existing manufacturing processes like embossing, injection molding, or roller techniques
Solution Approach 2:
The patent replaces complex multi-layer photovoltaic structures with a simpler single-layer structure enhanced by three-dimensional surface features on the light transmissive layer. This substitution achieves improved light absorption through optical effects rather than through increased material complexity
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 approach increases the photocurrent and overall electrical power output, reduces material costs, and enhances the stability and flexibility of photovoltaic devices by scattering light and minimizing angular dependence, leading to improved efficiency and longer device lifespan.
Implementation Method 1
featuring light transmissive layers with surface patterns that scatter light, increasing its path through the photovoltaically-active layer
Implementation Method 2
Photovoltaic cells convert optical energy to electrical energy
Implementation Method 3
a reflective second electrode
Data Source
AI summary
This disclosure provides photovoltaic cells and substrates with three dimensional optical architectures and methods of manufacturing the same. In particular, the disclosure relates to a continuously formed photovoltaic substrate, and to systems, devices, methods and uses for such a product, including the collection of solar energy.