Wet-Type Solar Cell Segmented Conductive Layer Design
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Solution Overview
Problem
Dye sensitized solar batteries face issues with internal short-circuiting due to the contact between the counter electrode conductive layer and the conductive layer, leading to reduced yield and efficiency, particularly when a porous insulating layer is thin or not adequately spaced, causing failures and performance drops.
Innovation Solution
A wet-type solar battery design with a conductive layer divided by a scribe line into regions with and without the photoelectric conversion layer, where the distance between the conductive layer and the photoelectric conversion layer is maintained between 50 µm and 500 µm, and the porous insulating layer's thickness is optimized to ensure adequate spacing and prevent short-circuiting, with specific thickness relationships defined for different configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the porous insulating layer is made thin to reduce manufacturing cost and improve light transmission, then manufacturing cost is reduced and light absorption is improved, but internal short-circuiting occurs between the counter electrode conductive layer and the conductive layer
Solution Approach 1:
The patent introduces a porous insulating layer as an intermediary component between the conductive layer and the counter electrode conductive layer. This intermediate layer acts as a physical barrier and electrical insulator, preventing direct contact between the two conductive layers while still allowing ion transport through its porous structure. The porous insulating layer thus mediates the interaction between the conductive layers, eliminating the short-circuiting problem without requiring complete removal of the insulating layer.
2Productivity
If the distance between the conductive layer and photoelectric conversion layer is reduced to increase active area, then photoelectric conversion efficiency is improved, but manufacturing precision requirements increase due to the need for precise spacing control
Solution Approach 1:
The patent specifies precise parameter ranges for the distance between the conductive layer and photoelectric conversion layer (50-500 µm) and for the porous insulating layer thickness. By defining these parameter ranges, the patent transforms the manufacturing challenge into a controllable parameter optimization problem. The specified distance range balances the need for close proximity (for efficiency) with the need for adequate spacing (for manufacturing tolerance), resolving the contradiction through quantitative parameter control.
3Power
If the solar battery area is increased to generate more power, then power output is improved, but voltage lowering occurs due to increased internal series resistance
Solution Approach 1:
The patent divides the solar battery structure into segmented regions with distinct functional zones. The conductive layer is divided into a first region (with photoelectric conversion layer) and a second region (without photoelectric conversion layer), separated by a scribe line. This segmentation allows for optimized current collection paths and reduced series resistance in different areas, enabling the solar battery to maintain lower internal resistance even as the overall area increases for higher power output.
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 design significantly reduces the occurrence of internal short-circuiting and improves the yield of the solar batteries by maintaining the integrity of the layers and ensuring effective photoelectric conversion, enhancing the overall performance and efficiency of the solar battery module.
Implementation Method 1
a wet-type solar battery to which photoinduced electron transfer of a metal complex has been applied
Implementation Method 2
a photoelectric conversion layer is composed of an electrolytic material and a photoelectric conversion material having an absorption spectrum in a visible light region by adsorbing a photosensitizing dye
Data Source
Figure 1(a)~1(b)
Figure 2
Figure 3
AI summary
It is an object of the present invention to provide a wet-type solar battery (10) capable of achieving suppressed occurrence of failure due to internal short-circuiting and improving yield and a wet-type solar battery module (20) including the wet-type solar battery (10). The wet-type solar battery (10) according to the present invention is a wet-type solar battery (10) including a support (1) composed of a light transmissive material and a stack in which a conductive layer (2), a photoelectric conversion layer (4) composed of a porous semiconductor not having a dense material, a porous insulating layer (5), and a counter electrode conductive layer (6) are stacked in this order on the support (1), the conductive layer (2) has a first region on which the photoelectric conversion layer (4) is stacked and a second region on which the photoelectric conversion layer (4) is not stacked, with a scribe line (3) lying therebetween, and the photoelectric conversion layer (4) is stacked on a part of a surface of the first region and a distance D from a peripheral portion of the first region facing the scribe line (3) to a peripheral portion of the photoelectric conversion layer (4) is not smaller than 50 µm.