Thin Glass Substrate Dye-Sensitized Solar Cell Module
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Solution Overview
Problem
Dye-sensitized solar cells face challenges in reducing weight without degrading performance, particularly when applied to large-area applications like vehicle roofs and glass windows, as conventional glass substrates are heavy and flexible substrates result in lower performance.
Innovation Solution
A method involving the use of a thin glass plate substrate for the counter electrode, combined with improved manufacturing processes that limit temperature to prevent warping, allowing for a significant reduction in module thickness while maintaining performance by using transparent conductive substrates and specific materials like FTO, IZO, and silver nano ink for low-temperature processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional glass substrates are used for counter electrode, then structural strength is maintained, but weight reduction is limited
Solution Approach 1:
The patent applies thin film technology by using a thin glass plate substrate with thickness of 0.1 to 1 mm instead of conventional thick glass substrates. This thin film approach reduces the substrate weight while maintaining sufficient structural strength for the solar cell module, directly resolving the contradiction between weight reduction and strength maintenance.
Solution Approach 2:
The patent changes the thickness parameter of the glass substrate from conventional thick (several mm) to thin (0.1-1 mm). This parameter change enables significant weight reduction while the controlled low-temperature processing ensures the thin substrate maintains its structural integrity, thus resolving the weight-strength contradiction.
2Weight of moving object
If thin glass plate substrate is used for counter electrode, then weight is reduced, but warping occurs during manufacturing
Solution Approach 1:
The patent changes the processing temperature parameter to low temperature (below softening point of glass) during manufacturing. This parameter change prevents thermal warping of the thin glass plate substrate while still enabling necessary manufacturing processes, thus resolving the contradiction between weight reduction and compositional stability.
Solution Approach 2:
The patent applies preliminary support structures during the manufacturing process to prevent warping of the thin substrate before final assembly. This preliminary action ensures the thin glass plate maintains its flatness throughout manufacturing, resolving the stability issue while keeping the weight reduction benefit.
3Stability of the object's composition
If low-temperature processing is used for thin substrate, then warping is prevented, but manufacturing complexity increases
Solution Approach 1:
The patent changes the temperature parameter to low temperature processing, which simplifies the manufacturing process by eliminating the need for complex warping control mechanisms and high-temperature equipment, thus reducing manufacturing complexity while maintaining substrate flatness.
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 method achieves a weight reduction of over 35% without degrading the solar cell's performance, making it suitable for applications like vehicle sunroofs and glass windows, with improved strength and fuel efficiency.
Implementation Method 1
stacking a transparent conductive material layer on a glass substrate to manufacture a transparent conductive substrate
Implementation Method 2
a system for generating electricity by using a photoelectric conversion mechanism configured to absorb visible light from a Ru-based pigment adsorbed to a TiO2 and form a photocurrent
Implementation Method 3
a Ru-based pigment adsorbed to a TiO2
Implementation Method 4
the working electrode 10 and the counter electrode 20 which are bonded to each other with a sealant 31
Data Source
AI summary
Disclosed are a dye-sensitized solar cell module and a method of manufacturing the same. The dye-sensitized solar cell module includes a working electrode formed by stacking a collector and a photo-electrode to which a dye is adsorbed on a transparent conductive substrate; a counter electrode formed by stacking a collector and a catalytic electrode on a transparent conductive substrate; and an electrolyte filled in a space between the working electrode and the counter electrode sealed by a sealant. A glass substrate for the working electrode of glass substrates forming the transparent conductive substrates for the electrodes is a thin glass plate substrate thinner than the glass substrate for the working electrode.