Stretchable Perovskite Solar Module Interconnects for Contoured Surfaces
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional solar cells, particularly perovskite solar cells (PSCs), face challenges in being flexible and stretchable enough to conform to complex, contoured surfaces, such as those found in modern automobile designs, due to high series resistance and lack of suitable interconnect designs that allow for multi-directional flexibility and stretchability.
Innovation Solution
A flexible and stretchable solar module design comprising flexible perovskite solar cells connected by deformable interconnects on a stretchable substrate, using materials like PDMS or vinyl, with exposed TCO layers and metal contacts, allowing for serial or parallel connections and conforming to contoured surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional solar cells are used, then high efficiency can be achieved, but the cells crack when flexed and cannot conform to contoured surfaces
Solution Approach 1:
The patent employs flexible substrates including stretchable polymers and thin film structures to replace rigid crystalline semiconductor substrates. This enables the solar cell to bend and stretch without cracking, directly resolving the contradiction between flexibility and structural integrity. The thin film architecture allows the cell to conform to contoured surfaces while maintaining operational reliability.
Solution Approach 2:
The patent introduces dynamic mechanical properties through stretchable substrates and deformable interconnects that can accommodate bending and stretching during operation. This dynamic design allows the solar cell to adapt to various surface geometries and mechanical deformations without compromising structural integrity, enabling both flexibility and reliability.
2Ease of manufacture
If TCO layers are used in flexible PSCs, then low-temperature processing is enabled, but high sheet resistance causes high series resistance
Solution Approach 1:
The patent employs composite transparent conductive structures combining TCO layers with metal underlayers or mesh structures. This composite approach maintains the low-temperature processing advantage of TCO while reducing sheet resistance through the added conductive metal components, thereby resolving the contradiction between ease of manufacture and electrical performance.
Solution Approach 2:
The patent modifies the electrical parameters of the TCO layer by adjusting thickness, composition, or adding overlaying metal layers to reduce sheet resistance. This parameter optimization allows low-temperature processing to be maintained while achieving lower series resistance, resolving the technical contradiction between manufacturing ease and electrical reliability.
3Reliability
If sequential laser scribing and deposition processes are used to reduce series resistance, then TCO resistance is reduced, but the process cannot be incorporated into flexible/stretchable module designs
Solution Approach 1:
The patent replaces rigid laser scribing and deposition processes with flexible metal underlayers or mesh structures that can be integrated into stretchable module designs. These flexible conductive structures reduce series resistance while accommodating bending and stretching, resolving the contradiction between electrical performance and mechanical adaptability.
Solution Approach 2:
The patent introduces dynamic flexibility into the interconnect structure by using deformable metal layers and mesh configurations that can stretch and bend with the module. This dynamic design maintains low series resistance while enabling the module to conform to various shapes and withstand mechanical deformation, resolving the contradiction between electrical reliability and mechanical versatility.
4Power
If solar modules are designed to cover larger vehicle surfaces, then solar energy generation increases, but the modules must conform to complex organic contours requiring multi-directional flexibility and stretchability
Solution Approach 1:
The patent divides the solar module into segmented flexible cells connected by deformable interconnects. This segmentation allows each cell to independently bend and stretch, enabling the overall module to conform to complex organic contours while maintaining electrical connectivity. The modular approach increases energy generation capacity by allowing larger coverage areas without proportionally increasing structural complexity.
Solution Approach 2:
The patent employs dynamic flexible substrates and deformable interconnect structures that can adapt to complex three-dimensional surfaces. This dynamic design enables the module to conform to organic contours while maintaining electrical performance, resolving the contradiction between increased power generation capacity and the complexity of achieving multi-directional flexibility and stretchability.
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 design enables solar modules to be flexible in multiple directions and stretchable, effectively forming to complex organic contours, reducing series resistance and enhancing the feasibility of solar implementation in the automotive industry.
Implementation Method 1
perovskite solar cells (PSCs)
Implementation Method 2
high sheet resistance of transparent conductive oxides (TCO)
Data Source
AI summary
High-performance perovskite solar cell (PSC) devices, arrays thereof, and modules manufactured on flexible and stretchable substrates using roll-to-roll high throughput manufacturing techniques. The flexible cells can be cut into strips and are connected via flexible and/or stretchable interconnects. The interconnect can be a layer deposited on a wavy surface of the stretchable substrate, a coiled or hinged wire, or a conductive paste that can be deformed prior to curing. The highly deformable solar modules can conform to complex organic contours and shapes, such as those that are common in vehicle designs. Such shapes typically require at least one axis of flex and at least one axis of stretch.