Solar Cell Module with Conductive Channel for Active Area Expansion
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Solution Overview
Problem
Conventional organic solar cell modules require sophisticated patterning techniques for thin film alignment, leading to increased inactive areas and reduced efficiency due to the need for precise contact between electrodes without any intervening layers, resulting in higher production costs and decreased active generation areas.
Innovation Solution
A solar cell module structure where a conductive channel is formed between the second electrode and the first electrode of neighboring cells, with the second electrode partially on the photoactive layer, eliminating the need for advanced patterning and allowing the entire photoactive layer to be formed as a thin film, and incorporating nanostructures to enhance conductive channel formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If thin films are patterned with slight and gradual shift of each layer to continuously connect counter electrodes, then electrode alignment is achieved, but manufacturing complexity increases and production cost increases
Solution Approach 1:
The patent extracts and eliminates the charge transport layers from the electrode connection region. By removing these intervening layers in the overlap area between adjacent solar cells, the counter electrodes can directly contact each other without requiring precise patterning alignment, thus simplifying the manufacturing process while maintaining electrical connectivity
Solution Approach 2:
Instead of using the conventional approach where charge transport layers are patterned to enable electrode contact, the patent inverts the approach by removing the charge transport layers specifically in the electrode overlap region. This inversion allows direct electrode contact without complex patterning, resolving the contradiction between alignment precision and manufacturing complexity
2Manufacturing precision
If thin films are patterned to connect counter electrodes, then electrode contact is achieved, but active area decreases and inactive area increases
Solution Approach 1:
The patent extracts the charge transport layers from the electrode connection regions, eliminating the need for inactive patterned areas. This allows the electrodes to extend to the edges of the active layer and make direct contact, maximizing the active area where electricity is generated while minimizing inactive areas used for alignment
Solution Approach 2:
The patent applies partial removal of charge transport layers only in the specific regions where electrode contact is needed, rather than patterning entire layers. This selective removal minimizes the impact on active area while achieving the necessary electrode connectivity
3Reliability
If charge transport layers are present between counter electrodes of neighboring cells, then electrode isolation is maintained, but electrical connection between cells is prevented
Solution Approach 1:
The patent extracts charge transport layers from the overlap regions between adjacent solar cells, creating direct electrical pathways for counter electrodes to contact. This removal enables series connection between cells while charge transport layers remain intact in non-overlap regions to maintain proper charge extraction and isolation functions
Solution Approach 2:
The patent applies different structural configurations to different regions of the solar cell module. In electrode overlap regions, charge transport layers are removed to enable direct electrical connection. In non-overlap regions, charge transport layers are maintained to ensure proper charge extraction and electrode isolation. This spatial variation in structure quality resolves the contradiction between isolation and connectivity
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 reduces the inactive area, increases the active generation area, and simplifies the manufacturing process by eliminating the need for advanced patterning, thereby improving the efficiency and cost-effectiveness of the solar cell module.
Implementation Method 1
a conductive channel is located between the second electrode and a first electrode of the neighboring solar cell
Implementation Method 2
each solar cell including a first electrode, a second electrode, and a photoactive layer located between the first electrode and the second electrode
Data Source
AI summary
Disclosed herein are a solar cell module and a method for manufacturing the same. The solar cell module comprises: a substrate; and a plurality of solar cells located on the substrate, each solar cell comprising a first electrode, a second electrode, and a photoactive layer located between the first electrode and the second electrode, wherein at least a portion of a second electrode is located on a photoactive layer of a neighboring solar cell, and a conductive channel is located between the second electrode and a first electrode of the neighboring solar cell. Therefore, a solar cell module having a structure in which every layer except for electrodes is entirely formed as a thin film may be provided. In addition, a solar cell module the module efficiency of which is improved by increasing the active area of each solar cell may be provided.