Polythiolene Coating for Planarizing Laser-Structured Optoelectronics
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Solution Overview
Problem
Existing methods for protecting optoelectronic components, particularly organic solar cells, from environmental factors and mechanical stress during the roll-to-roll production process are inadequate, leading to damage from bulges formed by laser structuring and poor adhesion between layers, which can cause short circuits and hinder further processing.
Innovation Solution
A polythiolene matrix coating formed by polymerizing a polyfunctional thiol and a polyfunctional alkene monomer is applied directly to the layer system, providing direct or diffusion contact to stabilize and planarize the laser-structured surface, offering protection against environmental influences and mechanical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a protective layer is applied to protect the optoelectronic component from environmental influences and mechanical stress, then the component is protected from damage, but the laser structuring process creates bulges that can cause short circuits and damage during winding
Solution Approach 1:
The patent applies a protective coating before the winding process to prevent damage from bulges formed during laser structuring. The coating is applied in advance to the optoelectronic component, creating a protective layer that stabilizes the surface and prevents short circuits during subsequent handling and winding operations.
Solution Approach 2:
The protective coating acts as an intermediary layer between the laser-structured surface with bulges and the winding process. This intermediate layer fills or covers the bulges, providing a smooth protective surface that prevents direct contact and potential short circuits between adjacent components during winding.
2Reliability
If existing protective methods are used, then some protection is provided, but adhesion between layers is poor and the component remains vulnerable to damage during processing
Solution Approach 1:
The patent employs a composite protective coating system consisting of multiple layers with different functions. The coating comprises a polymeric base layer providing adhesion to the substrate, and an overlying protective layer providing mechanical protection and environmental barrier. This composite structure combines the advantages of different materials to achieve both strong adhesion and effective protection.
Solution Approach 2:
The patent modifies the properties of the protective coating by controlling parameters such as crosslinking density, polymer composition, and layer thickness. These parameter changes optimize both the adhesion strength to the substrate and the protective properties against mechanical stress and environmental influences.
3Productivity
If the optoelectronic component is processed in roll-to-roll method, then productivity is improved, but the component is exposed to mechanical stress and environmental factors during handling
Solution Approach 1:
The protective coating is applied in advance during the roll-to-roll production process, before the component undergoes further handling and winding operations. This preliminary protective action ensures that the component is already protected when subjected to mechanical stress and environmental exposure during high-speed manufacturing.
Solution Approach 2:
The patent uses a flexible thin-film protective coating that can withstand the mechanical stresses of roll-to-roll processing while providing continuous protection. The thin film conformally follows the substrate and can be applied and handled in the flexible roll-to-roll format without compromising protective functionality.
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
The coating effectively protects the layer system from damage, improves adhesion, prevents short circuits, and enables seamless integration into the roll-to-roll method, allowing for further processing without damaging the optoelectronic components.
Implementation Method 1
the coating comprising a polythiolene matrix, wherein the polythiolene matrix is formed by polymerization from at least one first monomer and one second monomer
Implementation Method 2
the coating is disposed on the optoelectronic component and has at least partial direct contact with the layer system and/or diffusion contact with the layer system
Data Source
AI summary
A coating for planarization and stabilization of a laser-structured surface of an optoelectronic component, the optoelectronic component having a layer system including a first electrode, a second electrode, and at least one photoactive layer, wherein the at least one photoactive layer is disposed at least partly between the electrodes, and wherein the layer system is laser-structured, the coating including a polythiolene matrix, wherein the polythiolene matrix is formed by polymerization from at least one first monomer and one second monomer, wherein the first monomer is a polyfunctional thiol having at least three thiol groups, the second monomer is a polyfunctional alkene having at least two C—C double bonds, and the coating is disposed on the optoelectronic component and has at least partial direct contact with the layer system and/or diffusion contact with the layer system for at least the first monomer and/or the second monomer.