Flexible Solar Cell Coating to Prevent Tack Marks
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Thin and flexible solar cells used in solar-powered devices can warp and partially contact the transparent cover, leading to tack marks due to adhesion, which affects the appearance and power generation efficiency.
Innovation Solution
A solar cell design featuring a flexible power-generating layer covered by a resin layer and an adhesion-preventing layer made of inorganic material with a surface roughness of 1 nm to 500 nm, which reduces adhesion to the transparent plate while maintaining high light transmittance and preventing tack marks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a thin and flexible solar cell is used, then the solar cell can be made lightweight and adaptable, but the solar cell may warp and partially contact the transparent plate causing tack marks
Solution Approach 1:
An adhesion preventing layer is introduced as an intermediary between the solar cell and the transparent plate. This layer has controlled surface roughness (Sz of 1 nm to 500 nm) that prevents direct adhesion between the solar cell and plate, thereby eliminating tack marks while allowing the thin, flexible solar cell structure to be maintained
Solution Approach 2:
The surface roughness parameter of the adhesion preventing layer is specifically controlled within the range of Sz 1 nm to 500 nm. This parameter change creates optimal conditions for preventing adhesion while maintaining light transmittance, resolving the contradiction between using thin flexible cells and preventing appearance defects
2Reliability
If an adhesion preventing layer with high surface roughness is applied, then tack marks are prevented, but light transmittance and power generation efficiency are reduced
Solution Approach 1:
The surface roughness Sz is precisely controlled within the optimal range of 1 nm to 500 nm. This parameter optimization achieves the dual benefit of preventing adhesion (tack marks) while maintaining sufficient light transmittance for effective power generation, thus resolving the contradiction between reliability and energy efficiency
Solution Approach 2:
The adhesion preventing layer is constructed from inorganic materials with specifically engineered surface properties. This composite approach combines adhesion prevention capabilities with high light transmittance, allowing both tack mark prevention and maintained power generation efficiency
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 solution effectively prevents tack marks and maintains power generation efficiency by ensuring the solar cell and transparent plate do not adhere, even when partially contacting, thus preserving the visual appearance and operational performance of solar-powered devices.
Implementation Method 1
a flexible power generating layer which photoelectrically converts light incident thereon through the transparent plate
Implementation Method 2
an adhesion preventing layer covering the surface of the resin layer and facing the transparent plate through a gap. The adhesion preventing layer is made of an inorganic material and has a surface roughness Sz of 1 nm or more and 500 nm or less
Data Source
AI summary
A solar cell covered with a transparent plate through a predetermined gap includes a flexible power generating layer which photoelectrically converts light incident thereon through the transparent plate, a resin layer covering a light receiving surface of the power generating layer, and an adhesion preventing layer covering the surface of the resin layer and facing the transparent plate through the gap. The adhesion preventing layer is made of an inorganic material and has a surface roughness Sz of 1 nm or more and 500 nm or less. Thus, the outermost surface of the solar cell is constituted by the adhesion preventing layer, so that no tack mark occurs even when partial contact occurs between the solar cell and the transparent plate which face each other through the gap. As a result, it is possible to prevent deterioration in appearance due to the tack mark.