Pre-patterned Insulating Polymer Layers for Organic Solar Cells
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Solution Overview
Problem
Current photovoltaic cells face inefficiencies due to the need for cumbersome and energy-intensive processes in creating patterned cathodes or anodes, and organic solar cells are prone to oxidation, leading to short lifetimes without effective encapsulation.
Innovation Solution
The development of photovoltaic cells with pre-patterned insulating polymeric layers that create interconnected regions between the anode and cathode, and the incorporation of dyes within these layers to enhance light absorption and emission, reducing the need for multiple coatings and improving encapsulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If patterned cathode or anode is created using conventional coating methods, then the photovoltaic cell can be fabricated, but the fabrication process becomes cumbersome and energy intensive requiring at least three coating cycles
Solution Approach 1:
The patent applies preliminary action by pre-patterned insulating polymeric layers before depositing the cathode or anode. The insulating layer is pre-formed with a pattern that defines the electrode regions, allowing the conductive layer to be deposited in a single continuous coating step without requiring multiple masking and coating cycles. This resolves the contradiction by simplifying the fabrication process and reducing energy consumption while maintaining the necessary electrode patterning.
2Ease of manufacture
If patterned cathode or anode is created, then the photovoltaic cell structure is formed, but dead spaces are created which reduce the efficiency of the photovoltaic cells
Solution Approach 1:
The patent uses thin film insulating polymeric layers that can be precisely patterned to define electrode regions while minimizing dead spaces. The thin film nature allows for precise control over the pattern geometry, ensuring that the conductive electrodes are formed with minimal gaps and optimal coverage of the active layer, thereby maintaining high cell efficiency while achieving the necessary electrode patterning.
3Device complexity
If organic solar cell is used without encapsulation, then the device structure is simple, but the cell is prone to oxidation at the interface between the organic polymeric layer and the electrical contacting layer limiting lifetime to a few hours
Solution Approach 1:
The patent introduces an insulating polymeric layer as an intermediary between the organic polymeric layer and the electrical contacting layer (cathode or anode). This intermediary layer prevents direct contact between the organic material and the metal electrode, thereby preventing oxidation at the interface. The insulating layer is carefully designed to be electrically insulating yet allow for efficient charge extraction, resolving the contradiction by extending device lifetime without significantly increasing structural complexity.
4Reliability
If inverted geometry photovoltaic cell with MoO3 layer is used to reduce oxidation, then the extent of oxidation is reduced, but the coating process becomes more power consuming
Solution Approach 1:
The patent changes the material parameter from metal oxide (MoO3) to organic insulating polymers. The insulating polymeric layers are deposited using solution-based methods that consume significantly less energy compared to the vacuum evaporation required for MoO3. This parameter change maintains the oxidation protection function while dramatically reducing power consumption during the coating process.
5Reliability
If expensive high work function metals like platinum or gold are used to reduce oxidation, then the extent of oxidation is reduced, but there is substantial cost penalty and sophisticated setup is required
Solution Approach 1:
The patent replaces expensive precious metals (platinum, gold) with inexpensive organic insulating polymers. These polymer layers provide the necessary oxidation protection function at a fraction of the cost and can be deposited using simple solution-based techniques that do not require sophisticated vacuum equipment. The insulating layers are thin and can be processed at low temperatures, making the manufacturing process much more accessible and cost-effective.
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 simplifies the fabrication process, reduces energy consumption, and significantly extends the lifespan of photovoltaic cells by minimizing oxidation, while maintaining efficiency comparable to traditional methods.
Implementation Method 1
an insulating polymeric layer having dye incorporated therein being disposed between the anode and the cathode, said dye absorbing light energy of a first wavelength range and emitting light energy at a second wavelength range
Implementation Method 2
said dye absorbing light energy of a first wavelength range and emitting light energy at a second wavelength range
Implementation Method 3
an active layer disposed between the anode and the pre-patterned insulating polymeric layer, the said active layer generating charge carrier upon excitation by light
Data Source
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AI summary
The present disclosure relates to photo voltaic cells that are more efficient and stable than conventional photo voltaic cells. The present disclosure also relates to process for preparing such photo voltaic cells, which is inherently low-cost, less complex and results in a stable device.