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    • 专利摘要:
    ABSTRACT The present disclosure relates to solar cell devices for harvesting solar energy and methods of manufacture therefor. A solar cell device (51) comprises at least two adjacent solar cell stripes (2a, 2b) being serially arranged on a substrate (5). Each solar cell stripe (2a, 2b) comprises a first electrode layer stack (7), a second electrode layer stack (9) and at least one intermediary photocurrent generating layer (11). The first electrode layer stack (7) and the second electrode layer stack (9) are horizontally displaced in mutually opposite directions in relation to the intermediary photocurrent generating layer (11), defining a power conversion area (B) comprising the first electrode layer stack (7), the second electrode layer stack (9) and the intermediary photocurrent generating layer (11). The power conversion areas (B) are arranged at a first mutual distance (a) on a substrate (5). The solar cell device (51) further comprises folds (F', F") provided between the at least two solar cell stripes (2a, 2b), the folds (F', F") at least including the substrate (5). The folds (F', F") are arranged in the shape of a Z including a first fold (F') having a first folding angle (al) and a second fold (F") in a direction opposite the first fold (F'), the second fold (F") having a second folding angle (a2), wherein both the first and second folding angles (al, a2) are acute angles, whereby a second mutual distance (c) representing the mutual distance (a) between the power conversion areas (B) of the respective solar cell stripes (2a, 2b) is less than said first mutual distance (a).
    公开号:SE1450809A1
    申请号:SE1450809
    申请日:2014-07-01
    公开日:2016-01-02
    发明作者:Anders Elfwing；Jonas Bergqvist
    申请人:
    IPC主号:
    专利说明:

    SOLAR CELL DEVICE AND METHOD FOR MANUFACTURE TECHNICAL FIELD The present disclosure relates to solar cell devices for harvesting solar energy and methods of manufacture therefor.
    BACKGROUND With diminishing fossil fuels and increased awareness of the climate change, there is a global increase in the demand for renewable energy sources. Solar energy is being viewed as one of the most available and reliable renewable energy sources. The solar energy can be harvested using solar cells.
    In a basic configuration, a solar cell comprises three layers: a bottom electrode layer, a photo current generating layer, and a top electrode layer. In the photo current generating layer, incident light is converted into electrical current. The bottom and top electrode layers are necessary to extract the current.
    There are several different types of solar cells, e.g. silicon based solar cells and thin organic photo-voltaic (OPV) solar cells. OPVs can be manufactured in thin and flexible structures by means of printing onto a substrate, e.g. a plastic or paper with plastic coating. The solar cells are printed in long stripes that are interconnected to solar cell devices. The direction of the stripes is perpendicular to a current flow through the interconnected solar cells.
    In printed OPVs an electrical serial connection between adjacent solar cell stripes is commonly achieved by providing a connection, e.g. an overlap, between the bottom electrode and the top electrode of adjacent solar cells. However, unless it is possible to perform a high precision printing process, this implies that an area between each two adjacent solar cell stripes on the substrate will be dedicated to the electrical connection. This area is wasted from a solar power conversion perspective; solar energy is only harvested in the area including all three layers. When a solar cell device includes multiple such electrical connection areas, this will have a significant impact on the photocurrent output per area unit, i.e. lowering performance per area unit. 2 There is a need for a solution that improves the performance per area unit without the need for significantly improved precision in the manufacturing process. In particular, there is a need for a solution increasing a ratio between a total power conversion area and a total light exposed area of a solar cell device.
    SUMMARY The object of the present disclosure is to provide devices and methods for harvesting energy with solar cells which seek to mitigate, alleviate, or eliminate one or more of the above-identified deficiencies in the art and disadvantages singly or in any combination.
    The present disclosure presents methods and devices to increase the ratio between a total power conversion area and a total light exposed area of a solar cell device without demanding a more precise manufacturing technique.
    The solution proposes that a part of the area, comprising a non-power conversion area, is folded, by at least one fold. The fold/s is/are performed in such a way that the ratio between the total power conversion area and the total light exposed area of the solar cell device is increased.
    The proposed technique relates to a solar cell device comprising at least two adjacent solar cell stripes being serially arranged on a substrate. Each solar cell stripe comprises a first electrode layer stack, a second electrode layer stack and at least one intermediary photocurrent generating layer. The first electrode layer stack and the second electrode layer stack are horizontally displaced in mutually opposite directions in relation to the intermediary photocurrent generating layer. A power conversion area is defined comprising the first electrode layer stack, the second electrode layer stack, and the intermediary photocurrent generating layer. Adjacent power conversion areas are arranged at a first mutual distance on the substrate.
    The solar cell device further comprises at least one fold provided between the at least two solar cell stripes, the fold at least including the substrate, whereby a second mutual distance representing the mutual distance between the power conversion areas of the respective solar cell stripes is less than said first mutual distance. 3 An advantage of this is that the ratio between the total power conversion area and the total light exposed area of the solar cell device is increased. This is attained by providing at least one fold where a significant part of the redundant area, i.e. the area dedicated to electrical connections not participating in the power conversion, is reduced from the light exposed area of the solar cell device. This gives a more energy efficient solar cell device. That is, a smaller area covered with solar cell stripes is required to achieve the same electrical power delivery. Moreover, the need of a precise, which often is equivalent to an expensive and slow manufacturing technique, is reduced.
    According to an aspect of the disclosure, the solar cell stripes are printed on said substrate.
    Printed solar cells are advantageous since they are cheap and fast to produce. Printed solar cell stripes can also easily be mass produced in large volumes for mounting on large areas, e.g. in large photovoltaic parks in desserts, or as parts of house roofs or façades.
    According to a further aspect of the disclosure, an electrical serial connection is provided between the at least two solar cell stripes so that the first electrode layer stack of a first solar cell stripe is electrically connected to a second electrode layer stack of an adjacent solar cell stripe when printed. This is advantageous since existing well-tried printing techniques can be utilized.
    According to another aspect of the disclosure, an electrical serial connection is provided between the at least two solar cell stripes so that the first electrode layer stack of a first solar cell stripe is electrically connected to a second electrode layer stack of an adjacent solar cell stripe by means of the fold between the at least two solar cell stripes.
    This is advantageous since large parts of the area containing electrical connection that does not contribute to the power conversion can be excluded from the light exposed area, thus boosting the power efficiency per area unit of the solar cell device. Moreover, the risk of creating electrical short circuiting between adjacent solar cell stripes in the printing process is removed.
    According to aspects, a material of the substrate comprises paper. Furthermore, according to other aspects, a material of the substrate comprises a polymer. These materials often have low purchase price and are in many cases environmental beneficial since they are recyclable. 4 Moreover, the variety of available paper and polymer materials makes it possible to find suitable material properties for many different solar cell applications.
    According to yet other aspects of the disclosure, the fold is arranged in the shape of a Z including a first fold having a first folding angle and a second fold in a direction opposite the first fold, the second fold having a second folding angle, wherein both the first and second folding angles are acute angles. By utilizing a fold arranged in the shape of a Z, a significant part of the redundant area, i.e. the area dedicated to electrical connections, is then, by at least one fold, reduced from the light exposed area of the solar cell device. This means that the ratio between the total power conversion area and the total light exposed area of a printed solar cell device, is increased and thereby is the efficiency of the solar cell device boosted.
    According to further aspects of the disclosure, the device further comprises a coating, covering a top or bottom surface of the solar cell device. According to one aspect of the disclosure, if the fold to be achieved is of the shape of a Z and there is a need of a coating to bring about the desired shape of the solar cell device. Furthermore, a coating is advantageous in that it protects the solar cell device from oxygen and water.
    The proposed technique further relates to a method for manufacturing a solar cell device wherein at least two solar cell stripes are arranged on a substrate. Each of the adjacent solar cell stripes comprises a first electrode layer stack, a second electrode layer stack and at least one intermediary photocurrent generating layer. The first electrode layer stack and the second electrode layer stack are horizontally displaced in mutually opposite directions in relation to the intermediary photocurrent generating layer. A power conversion area is defined comprising the first electrode layer stack, the second electrode layer stack, and the intermediary photocurrent generating layer. Adjacent power conversion areas are arranged at a first mutual distance on the substrate.
    The method further relates to a step of providing at least one fold between the at least two adjacent solar cell stripes. The fold at least including the substrate, whereby a second mutual distance representing the mutual distance between the power conversion areas of the respective solar cell stripes is less than said first mutual distance. The advantages of these aspects have already been mentioned when the solar cell device is discussed and consequently they are not repeated again.
    According to another aspect of the method for manufacturing a solar cell device, wherein the manufacturing is performed in an automated printing process and wherein the folding is performed as an automated step following the printing. The advantages are that the number of manual manufacturing steps demanding manpower is reduced. That is, this feature reduces production costs and speeds up the manufacturing process.
    BRIEF DESCRIPTION OF THE DRAWINGS The invention will be further described with reference to the accompanying drawings.
    Figure la shows a perspective view of a prior art solar cell device comprising solar cell stripes arranged on a substrate; Figure lb shows a cross section view of the prior art solar cell device of Figure la; Figure 2 shows a perspective view of a solar cell stripe arranged on a substrate; Figure 3a shows a perspective view of a plurality of solar cell stripes arranged on a substrate; Figure 3b shows a cross section view of the plurality of solar cell stripes arranged on a substrate; Figure 4 shows a solar cell device according to one embodiment of the invention; Figure 5 shows a cross section view of a solar cell device according to another embodiment of the invention; Figure 6 shows a cross section view of a solar cell device according to yet another embodiment of the invention; Figure 7 shows a cross section view of a solar cell device according to one embodiment of the invention; Figure 8 shows a cross section view of a solar cell device according to one embodiment of the invention; Figure 9 shows a top view of any of the solar cell devices of Figures 4-8. 6 DETAILED DESCRIPTION Aspects of the present disclosure will be described more fully hereinafter with reference to the accompanying drawings. The devices and methods disclosed herein can however be realized in many different forms and should not be construed as being limited to the aspects set forth herein. Like numbers in the drawings refer to like elements throughout the text.
    The terminology used herein is for the purpose of describing particular aspects of the disclosure only, and is not intended to limit the disclosure. As used herein, the singular forms "a", ''an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise.
    It is an object of the present disclosure to increase the ratio between a total power conversion area and a total light exposed area of a solar cell device comprising serially arranged solar cell stripes.
    The solution proposes that a part of the area, comprising a non-power conversion area, is folded, by at least one fold F. The fold/s F is/are performed in such a way that the ratio between the total power conversion area and the total light exposed area of the solar cell device is increased.
    Figure la shows a perspective view of a prior art solar cell device 1 comprising solar cell stripes 3 serially arranged on a substrate 5. Each solar cell stripe comprises a first and a second electrode layer stack and an intermediary photocurrent generating layer. An electrode layer stack includes at least an electrode layer, but could also include additional printed layer contributing to the function of the electrode. In the following, the term electrode layer stack and electrode layer will be used interchangeably. When printed on the substrate, the layers are displaced in respect to one another and partially overlapping thereby providing an electrical bridge between the top and the bottom electrode of adjacent solar cell stripes.
    A key issue in OPVs is the high electrical resistance in the cells which will cause a power loss according to P=R x 12, where P=power, R=electrical resistance, and 1=electrical current. To minimize the power loss, the current should be as low as possible. This is achieved by providing multiple solar cell stripes on the substrate and electrically connecting the solar cell stripes 3 in serial connections so that adjacent solar cell stripes are serially connected. 7 In the example of Figure la, an electrical serial connection is provided between adjacent solar cell stripes 3a, 3b by electrically connecting the first electrode layer stack 7 of a first solar cell stripe 3a to a second electrode layer stack 9 of an adjacent solar cell stripe 3b when printed. The first electrode layer stack 7 of a first solar cell stripe 3a is extended on the substrate 5 in order to be engaged with the second electrode layer stack 9 of an adjacent solar cell stripe 3b.
    Short circuiting is prevented by letting the first electrode layer stack 7 and the second electrode layer stack 9 be horizontally displaced in mutually opposite directions in relation to the intermediary photocurrent generating layer 11.
    Figure lb shows a cross section view of the prior art solar cell device 1 of Figure la. For each solar cell stripe having a length I, a width b is indicated to represent a side of a power conversion area B=b*I. The term power conversion area is used to represent the area of the solar cell stripe where solar energy is transformed into electrical current. The power conversion areas are separated by a distance a on the substrate. Thus, each solar cell device also includes a plurality of separation areas a*I, where no solar power is generated. In the disclosed prior art solution, the separation area is dedicated to the electrical connection.
    When an area of a solar cell device includes multiple such separation areas, this will have a significant impact on the photocurrent output per area unit, i.e. lowering performance per area unit.
    In Figure 2, the general structure of a solar cell stripe 2 is shown. Each solar cell stripe comprises a first electrode layer stack 7, a second electrode layer stack 9 and at least one intermediary photocurrent generating layer 11. The first electrode layer stack 7 and the second electrode layer stack 9 are horizontally displaced in mutually opposite directions in relation to the intermediary photocurrent generating layer 11. The solar energy is transformed in the photocurrent generating layer 11 and extracted as electrical current by means of the electrode layer stack stacks.
    Figure 3a depicts a perspective view of solar cell stripes 2, 2a and 2b being serially arranged, e.g. printed, on a substrate 5. Each solar cell stripe 2, 2a, 2b has the general configuration disclosed in Figure 2. Figure 3b discloses a cross section view of two solar cell stripes 2a, 2b of Figure 3a. A power conversion area B having a width b is defined comprising the first electrode layer stack 7, the second electrode layer stack 9, and the intermediary photocurrent 8 generating layer 11. The second electrode layer stack 9 is transparent to radiation energy from the sun such that the radiation energy can be transformed into electrical current in the intermediary photocurrent generating layer 11. The power conversion areas B, i.e. the areas of the solar cell stripes where solar energy is actually transformed into electrical current, are arranged at first mutual distances a on the substrate. The solar energy is transformed into electrical current in the intermediary photocurrent generating layer 11, where the first and second electrode layer stack stacks 7, 9, are necessary in order to set up an electric potential difference to extract the current. In contrast to the previously disclosed prior art solutions of Figures la and lb, the structure disclosed in Figures 3a and b does not comprise any electrical connections connecting adjacent solar cell stripes 2a, 2b. In order to arrive at a solar cell device benefitting from power conversion in a plurality of solar cell stripes, electrical serial connections need to be provided between the disclosed solar cell stripes.
    Figures 4-8 illustrate cross section views of solar cell devices 41, 51, 61, 71, 81 including adjacent, electrically connected solar cell stripes 2, 3. A common denominator of the disclosed example embodiments of solar cell devices 41, 51, 61, 71, 81 is that a fold is provided between each pair of adjacent solar cell stripes of a solar cell device 41, 51, 61, 71, 81 so as to increase the photocurrent output per area unit gain. In accordance with an aspect of the disclosure, the fold provides the electrical connection between the adjacent solar cell stripes. The fold is provided in such a way that the ratio between the total power conversion area, the sum of all power conversion areas B of the solar cell device, and the total light exposed area of the solar cell device 41, 51, 61, 71, 81 is increased in comparison to a corresponding ratio prior to providing the fold. The example embodiments will be discussed in detail below.
    Figure 4 shows a cross section view of a solar cell device 41 according to one embodiment of the invention. The solar cell device 41 comprises partially overlapping solar cell stripes 3a, 3b in accordance with the disclosure of Figures la and b. An electrical serial connection is provided between the disclosed adjacent solar cell stripes 3a, 3b during the printing process so that the first electrode layer stack 7 of a first solar cell stripe 3a is electrically connected to a second electrode layer stack 9 of an adjacent solar cell stripe 3b when manufactured. The first electrode layer stack 7 of the first solar cell stripe 3a is extended on the substrate 5 in order to be engaged with the second electrode layer stack 9 of an adjacent solar cell stripe 3b.
    Short circuiting is prevented by letting the first electrode layer stack 7 and the second 9 electrode layer stack 9 be horizontally displaced in mutually opposite directions in relation to the intermediary photocurrent generating layer 11. The solar cell device 41 comprises at least one fold F. The fold F is provided between adjacent two solar cell stripes 3a, 3b, the fold F at least including the substrate 5, whereby a second mutual distance c representing the mutual distance between the power conversion areas B of the adjacent solar cell stripes 3 is less than said first mutual distance a, cf. Figure lb. The power conversion area B is defined as illustrated in Figure la and lb: B=b*I.
    The fold F is arranged in the shape of a Z including a first fold F' having a first folding angle al and a second fold F" in a direction opposite the first fold F', the second fold F" having a second folding angle a2, wherein both the first and second folding angles al, a2 are acute angles, having vertices of opposite directions. The Z-fold is attained by arranging the two folds F', F", where the first ford F' and the second fold F" are in opposite direction to the one other. Both folds F', F" are defined by acute angles al, a2. Furthermore, both folds F', F" are both located in the area in between adjacent power conversion areas B. A significant part of the redundant area, i.e. the area dedicated to electrical connections, is, by folding, reduced from the light exposed area of the solar cell device 41. This results in that the ratio between the total power conversion area and the total light exposed area of the printed solar cell device 41 is increased and thereby is the efficiency of the solar cell device 41 boosted. Figure 4 discloses folding of two adjacent solar cell stripes 3a, 3b, but the same folding structure could naturally also be applied to a greater number of solar cells stripes formed on a substrate.
    Figure 5 shows a cross section view of a solar cell device 51 according to another embodiment of the invention. In Figure 5, an electrical serial connection is provided between adjacent solar cells 2 so that the first electrode layer stack 7 of a first solar cell stripe 2a is electrically connected to a second electrode layer stack 9 of an adjacent solar cell stripe 2b by means of a Z-fold F between the at least two solar cell stripes 2a, 2b. Starting from solar cell stripes formed on a substrate as exemplified in Figure 3a and b, the second electrode layer stack 9 of the second solar cell stripe 2b is engaged with the first electrode layer stack 7 of an adjacent solar cell stripe 2a, by the means of the Z-fold. As previously discussed in relation to Figure 4, the fold is arranged in the shape of a Z. The Z-fold is obtained by folding two folds F', F", where the first fold F' and the second fold F" are in opposite direction to the one other.
    Furthermore, both folds F', F" are located in the area in between adjacent power conversion areas B, here represented by the conversion area length b. A significant part of a redundant area, i.e. an area not contributing to the power conversion in the optical device, is, by folding, removed from the light exposed area of the solar cell device 51. This results in that the ratio between the total power conversion area and the total light exposed area of the printed solar cell device 51 is increased and thereby is the efficiency of the solar cell device 51 boosted.
    Figure 5 discloses folding of two adjacent solar cell stripes 2a, 2b, but the same folding structure could naturally also be applied to a greater number of solar cells stripes formed on a substrate.
    Figure 6 depicts a cross section view of a solar cell device 61 according to another embodiment of the invention. The disclosed solar cell device 61 comprises two solar cell stripes 2a, 2b arranged on a substrate 5. In this embodiment the invention the fold F is made up of a series of folds between each two adjacent solar cell stripes 2a, 2b, here indicated as F. The series of folds provide a T-shape to at least the substrate 5. The fold F is situated between the power conversion areas B of the solar cell stripes 2a, 2b of the solar device 61. The fold F/series of folds further displaces parts of at least the substrate 5 in a direction away from the power conversion areas B of the solar cell stripes 2a, 2b. The series of folds comprises two folds in the vicinity of the edges of the power conversion areas B of adjacent solar cell stripes 2, wherein these two folds create angles y1 and y2 respectively, and an intermediate fold in between said other two folds, wherein the intermediate fold creates an angle 13. The angles y1 and y2 are both in the vicinity of 900 and the angle 13 is in the vicinity of 0°. The fold F/ series of folds result in a second mutual distance c between the power conversion areas B of adjacent solar cell stripes 2, wherein the second mutual distance c is shorter than the first mutual distance a.
    In the disclosed embodiment, the solar cell stripes 2a, 2b are not electrically connected before applying the fold. However, it will be appreciated by the person skilled in the art, that the same type of fold may be arranged also when having electrically connected stripes printed on a substrate. When having solar cell stripes 3 electrically connected prior to the folding, the focus of the folds F will be the displacement of at least the substrate 5 for a higher ratio between the power conversion area B and the total light exposed area of the solar cell device 61. Figure 6 discloses folding of two adjacent solar cell stripes 2a, 2b, but the same folding 11 structure could naturally also be applied to a greater number of solar cells stripes formed on a substrate.
    Figure 7 shows a cross section view of a solar cell device 71 according to another embodiment of the invention. The solar cell device 71 comprises a substrate 5 and adjacent solar cell stripes 3a, 3b, cf. Figure la and b. Each solar cell stripe 3a, 3b comprises a first electrode layer stack 7, a second electrode layer stack 9 and at least one intermediary photocurrent generating layer 11, the first electrode layer stack 7 and the second electrode layer stack 9 being horizontally displaced in mutually opposite directions in relation to the intermediary photocurrent generating layer 11, defining a power conversion area B comprising the first electrode layer stack 7, the second electrode layer stack 9, and the intermediary photocurrent generating layer 11. The first electrode layer stack 7 of the first solar cell stripe 3a is in engagement with the second electrode layer stack 9 of the second solar cell stripe 3b, so that an electrical connection is obtained, by means of a fold F including a series of folds: a first fold with a folding angle al and a second fold in a direction opposite the first fold with a folding angle a2 are provided between the solar cell stripes 3a, 3b, the folding angles al and a2 being the same, such that the power conversion areas B of the solar cell stripes 3a, 3b, lie parallel to each other, with a second mutual distance c and an inclination angle 13 with respect to a common plane P.
    The embodiment depicted in Figure 7 is in a staggered zigzag fold F. The main purpose of this would be to arrange the power conversion areas B to have an angle with respect to an underlying surface. Since the solar cell device 71 may be used in large photovoltaic parks in desserts, or as parts of house roofs or façades, where the incident light is incident at an angle with respect to the surface the solar cell device 71 is mounted on, there is a need to arrange the power conversion areas B so that they are directed towards the incident light.
    The embodiment of Figure 7 has the advantage that it directs the power conversion areas B towards the incident light, while simultaneously having as little as possible of the non-power converting region directed towards the incident light, effectively reducing a first distance a of Figures lb or 3b, to the second distance c. Figure 7 discloses folding of two adjacent solar cell stripes 3a, 3b, but the same folding structure could naturally also be applied to a greater number of solar cells stripes formed on a substrate. 12 Figure 8 shows a cross section view of a solar cell device 81 according to another embodiment of the invention. In the illustration of Figure 8, a solar cell device comprising three solar cell stripes 2, 2a, 2b serially arranged on a substrate 5 is disclosed. In this embodiment the invention comprises a series of folds F between each pair of adjacent solar cell stripes 2, 2a, 2b wherein the folds F comprises at least the substrate 5.
    Two middle folds F', F" are at acute angles with the vertices of the angles facing away from each other, such that the first electrode layer stack 7 of a first solar cell stripe 2a is electrically connected to a second electrode layer stack 9 of an adjacent solar cell stripe 2b by means of the two middle folds F', F" between the two solar cell stripes 2. A fold F" adjacent to the solar cell stripe 2a has a V-shape. Figure 8 discloses folding of three adjacent solar cell stripes, but the same folding structure could naturally also be applied to a greater number of solar cells stripes formed on a substrate.
    An advantage of this embodiment is that light that is not absorbed in the intermediary photocurrent generating layer 11 of one solar cell stripe 3a may be reflected to the power conversion area B of the adjacent solar cell stripe 3b, thereby increasing the overall efficiency of the solar cell device 81.
    Figure 9 shows a schematic top view of a solar cell device 91 according to another embodiment of the invention. The solar cell device 91 may further represent a top view of any of the solar cell devices 41, 51, 61, 71, 81 disclosed in Figures 4-8. In the disclosure of Figure 9, eight solar cell stripes are disclosed. However, in practice, each power conversion area of the solar cell device will be in the range of 3-10 mm, preferably 4-6 mm, which implies that a solar cell device including a plurality of stripes provided on a substrate will include many more solar cell stripes than those disclosed in Figure 9, e.g. some 100-200 stripes for a device having a width w of 1 meter.
    The solar cell device 91 comprises eight solar cell stripes 2,3, the plurality of solar cell stripes 2, 3 may however be any given number permitted by the size of the solar cell device 91.
    In the following, aspects applicable to one or more of the previously discussed embodiments in Figures 4-9 will be presented. 13 In one embodiment the solar cell stripes 3 are printed. The printing may be of slot-die coating technique.
    In some embodiments the material of the first electrode layer stack stacks 7 is metal. This can be exemplified by aluminium coated with e.g. titanium or chrome to prevent oxidation. By utilizing a metal as the material of the first electrode layer stack 7, a specular reflection of the solar radiation, as described earlier, is achieved without a reflective layer.
    It is further noted that according to some other embodiment, additional layers are arranged between the substrate 5 and the first electrode layer stack 7. In one embodiment the first and the second electrode layer stack 7, 9, comprise PEDOT: PSS. To achieve a difference in electrical potential between the first and second electrode layer stack 7, 9, an intermediate layer is arranged between the first electrode layer stack 7 and the second electrode layer stack 9. In one embodiment this intermediate layer comprises ZnO.
    It is further noticed that in some embodiments the material of the first electrode and the second electrode layer stack 7, 9, are different, i.e. combinations of the above mentioned materials of the electrode layer stack stacks and intermediate layers are common. An embodiment is to utilize a metal as material of the first electrode layer stack 7 and a second electrode 9 made out of PEDOT: PSS.
    According to one scenario, the material of the substrate 5 comprises paper. In one example the paper is covered with thin PET polyester, to make the surface smooth.
    According to another embodiment, the material of the substrate 5 comprises a polymer.
    According to further aspects, embodiments of solar cell devices 41, 51, 61, 71, 81 and 91 as disclosed in Figures 4-9, further comprise a coating covering a top or bottom surface of the solar cell device. In one embodiment this coating comprises a material having water and/or oxygen resistant properties. In another embodiment of the disclosure, the fold F of the solar cell device 41, 51, 61, 71, 81, 91 may need to be fixed or glued in order to retain a desired shape. The coating may then act as an adhesive to help retaining said shape. If the electrical serial connection is to be established by the fold F, the coating, in one example, ensures that the first electrode layer stack 7 are kept in contact with the second electrode layer stack 9 of an adjacent solar cell stripe 2,3. In one embodiment the coating is applied under pressure. In 14 another embodiment the material of the coating is chosen from materials within the categories glue, conducting glue, cloth, sticky films either in combination or by itself.
    In yet another example, a sticky substance is added to the electrodes before the folding process. The solar cell device 41, 51, 61, 71, 81, 91 is then cured in order to preserve the connection between electrodes 9, 11, of adjacent solar cell stripes.
    In the disclosure above, the solar cell device has been described in terms of solar cell stripes, each solar cell stripe including a first and a second electrode layer stacks and a photocurrent generating layer. However, it should be noted that the disclosure is not limited to solar cell devices only including these layers but is equally applicable to solar cell devices also including any other types of contributing layers, e.g. photocurrent facilitating layers and electrode enhancing layers.
    In yet another embodiment where the solar cell stripes 3, 3a, 3b are electrically serially connected in the printing process, cf. Figure 4, the process of covering is less crucial according to the aspect of keeping adjacent electrode layer stack stacks 9, 11 in engagement with each other. This is due to the fact that the electric serial connection is established in the printing process.
    The proposed technique further relates to a method for manufacturing a solar cell device 41, 51, 61, 71, 81, 91 wherein at least two solar cell stripes 2, 3 are arranged on a substrate 5. Each of the solar cell stripes 2,3 comprising a first electrode layer stack 7, a second electrode layer stack 9 and at least one intermediary photocurrent generating layer 11. The first electrode layer stack 7 and the second electrode layer stack 9 are horizontally displaced in mutually opposite directions in relation to the intermediary photocurrent generating layer 11. A power conversion area B is defined comprising the first electrode layer stack 7, the second electrode layer stack 9, and the intermediary photocurrent generating layer 11. The power conversion area B is defined as the width b of the conversion area times the length of the solar cell device. Moreover, the power conversion areas B are arranged at a first mutual distance a. The method of manufacturing further comprises a step of providing at least one fold F between the at least two adjacent solar cell stripes 2, 3. The fold F includes at least the substrate 5, whereby a second mutual distance c representing the mutual distance between the power conversion areas B of the respective solar cell stripes 2,3 is less than said first mutual distance a. In one embodiment, this step is performed in such a way that the distance between adjacent power conversion areas B is reduced. In one embodiment this step makes the precision of the manufacturing technique less crucial. The reason is that the area dedicated to electrical connections between two adjacent solar cell stripes 2, 3 on the substrate 5, can be set to a distance where the chance of obtaining electrical short circuiting between adjacent solar cell stripes 2, 3 is diminished. Parts of this additional non-power conversion area are then reduced from the light exposed area of the solar cell device 41, 51, 61, 71, 81, 91 by the method that folds at least the substrate 5.
    According to one aspect of the disclosure, the step of folding comprises preparing a paper substrate 5 for folding by bowing the paper where the fold F is to be provided.
    According to another aspect of the disclosure, the step of folding comprises preparing a polymer substrate 5 for folding by perforating the where the fold F is to be provided.
    According to another aspect, the method of manufacturing comprises providing an electrical serial connection between the at least two solar cell stripes 2 when providing said fold F so that the first electrode layer stack 7 of a first solar cell stripe 3a is electrically connected to a second electrode layer stack 9 of an adjacent solar cell stripe 2 by means of the fold F between the at least two solar cell stripes 2.
    According to another aspect of the disclosed method, the manufacturing is performed in an automated printing process and the folding is performed as an automated step following the printing. In one embodiment the folding process is followed by an automated coating process where a top or bottom surface of the solar cell device 41, 51, 61, 71, 81, 91 is covered by a coating. In one embodiment this coating process comprises coverage of a material having water and/or oxygen resistant properties. In another embodiment of the method, the fold F of the solar cell device 51, 61, 71, 81, 91 is fixed or glued in order to achieve a desired shape.
    That is e.g. if the fold F to be achieved is of the shape of a Z, and the material has non-flexible material properties, then there might be a need of a coating covering to bring about a flat solar cell device 41, 51, 61, 71, 81, 91. If the electrical serial connection is to be established by the fold F, the coating process, in one example, ensure that first electrode layer stack 7 are kept in engagement with the second electrode layer stack 9 of an adjacent solar cell stripe 2.
    In one other embodiment the coating process applies the cover under pressure. 16 In yet another example of the method, a sticky substance is added to the electrode layer stack stacks 7, 9, before the folding process. After the folding the solar cell device 41, 51, 61, 71, 81, 91 a curing process preserves the connection between electrode layer stack stacks 7, 9, of adjacent solar cell stripes 3a, 3b.
    According to one embodiment of the method of the invention, a plurality of solar cell stripes 2, 3 is printed on a substrate as disclosed in Figures la and lb or Figures 3a and 3b. While said illustrations depicts two solar cell stripes 2a, 2h; 3a, 3b on a substrate 5, an operational solar cell device 41, 51, 61, 71, 81, 91 typically comprises more solar cell stripes 2, 3. As has been described above, the current must be kept low in order to avoid power loss. By printing solar cells stripes 2, 3, the power conversion areas B can be extended in the direction perpendicular to the current flow direction, while keeping the dimension of the solar cell stripes 2; 3, limited in the current flow direction. With a width of the power conversion area B being in the range of 3-10 mm and the solar cell stripes 2, 3 having a first mutual distance a of 3 mm, this means that a first solar cell device of one meter, measured in the direction of the current flow, typically comprises about 75-170 solar cell stripes 2, 3. This means that a solar cell device 1 according to prior art will typically have a significant total non-power conversion area for every 1 m of a printed solar cell device. In this embodiment of the method of the invention, the folding step provides a series of folds F between each solar cell stripe 2, 3. According to an aspect of the disclosure, the folding step also comprises providing an electrical serial connection between the solar cell stripes of the folded solar cell device 51, 61, 71, 81, 91 so that the first electrode layer stack 7 of a first solar cell stripe 2a is electrically connected to a second electrode layer stack 9 of an adjacent solar cell stripe 2b by means of the fold F between the two solar cell stripes 3a, 3b.
    A solar cell device 41, 51, 61, 71, 81, 91 according to any embodiment of the invention, as depicted in Figures 4-9, typically comprises more than two solar cell stripes 2, 3.
    All embodiments described can be carried out by themselves or in combination with each other. 17
    权利要求:
    Claims (11)
    [1] 1. A solar cell device (41, 51, 61, 71, 81, 91) comprising at least two adjacent solar cell stripes (2a, 2h; 3a, 3b) being serially arranged on a substrate (5), each solar cell stripe (2a, 2h; 3a, 3b) comprising a first electrode layer stack (7), a second electrode layer stack (9) and at least one intermediary photocurrent generating layer (11), the first electrode layer stack (7) and the second electrode layer stack (9) being horizontally displaced in mutually opposite directions in relation to the intermediary photocurrent generating layer (11), defining a power conversion area (B) comprising the first electrode layer stack (7), the second electrode layer stack (9), and the intermediary photocurrent generating layer (11), the power conversion areas (B) arranged at a first mutual distance (a) on the substrate characterised in that the solar cell device (41, 51, 61, 71, 81, 91) further comprises at least one fold (F) provided between the at least two solar cell stripes (2a, 2h; 3a, 3b), the fold (F) at least including the substrate (5), whereby a second mutual distance (c) representing the mutual distance between the power conversion areas (B) of the respective solar cell stripes (2a, 2h; 3a, 3b) is less than said first mutual distance (a).
    [2] 2. The solar cell device (41, 51, 61, 71, 81, 91) according to claim 1, characterised in that the solar cell stripes (2a, 2b; 3a, 3b) are printed on said substrate (5).
    [3] 3. The solar cell device (41, 51, 61, 71, 81, 91) according to claim 2, characterised in that an electrical serial connection is provided between the at least two solar cell stripes (3a, 3b) so that the first electrode layer stack (7) of a first solar cell stripe (3a) is electrically connected to a second electrode layer stack (9) of an adjacent solar cell stripe (3b) when printed.
    [4] 4. The solar cell device (41, 51, 61, 71, 81, 91) according to claim 2, characterised in that an electrical serial connection is provided between the at least two solar cell stripes (2a, 2b) so that the first electrode layer stack (7) of a first solar cell stripe (2a) is electrically connected to a second electrode layer stack (9) of an adjacent solar cell stripe (2b) by means of the fold (F) between the at least two solar cell stripes (2a, 2b).
    [5] 5. The solar cell device (41, 51, 61, 71, 81, 91) according to any of the preceding claims, characterised in that a material of the substrate (5) comprises paper. 18
    [6] 6. The solar cell device (41, 51, 61, 71, 81, 91) according to any of the preceding claims, characterised in that a material of the substrate (5) comprises a polymer.
    [7] 7. The solar cell device (41, 51, 61, 71, 81, 91) according to any of the preceding claims, characterised in that the fold (F) is arranged in the shape of a Z including a first fold (F) having a first folding angle (al) and a second fold (F) in a direction opposite the first fold (F), the second fold (F) having a second folding angle (a2), wherein both the first and second folding angles (al, a2) are acute angles.
    [8] 8. The solar device cell (41, 51, 61, 71, 81, 91) according to any of the preceding claims, characterised in that the solar cell device (41, 51, 61, 71, 81, 91) further comprises a coating covering a top or bottom surface of the solar cell device (41, 51, 61, 71, 81, 91).
    [9] 9. A method for manufacturing a solar cell device (41, 51, 61, 71, 81, 91) wherein at least two solar cell stripes (2a, 2h; 3a, 3b) are arranged on a substrate (5), each solar cell stripe (2a, 2h; 3a, 3b) comprising a first electrode layer stack (7), a second electrode layer stack (9) and at least one intermediary photocurrent generating layer (11), the first electrode layer stack (7) and the second electrode layer stack (9) being horizontally displaced in mutually opposite directions in relation to the intermediary photocurrent generating layer (11), defining a power conversion area (B) comprising the first electrode layer stack (7), the second electrode layer stack (9), and the intermediary photocurrent generating layer (11), the power conversion areas (B) arranged at a first mutual distance (a) on the substrate; wherein the method is characterised in a step of providing at least one fold (F) between the at least two adjacent solar cell stripes (2a, 2h; 3a, 3b), the fold (F) at least including the substrate (5), whereby a second mutual distance (c) representing the mutual distance between the power conversion areas (B) of the respective solar cell stripes (2a, 2b; 3a, 3b) is less than said first mutual distance (a).
    [10] 10. The method for manufacturing a solar cell device (41, 51, 61, 71, 81, 91) according to claim 9, characterised in providing an electrical serial connection between the at least two solar cell stripes (2a, 2b) so that the first electrode layer stack (7) of a first solar cell stripe (2a) is electrically connected to a second electrode layer stack (9) of an adjacent solar cell stripe (2b) by means of the fold (F) between the at least two solar cell stripes (2a, 2b). 51, 61, 71, 81, 91) according to claim an automated printing process and p following the printing. 1/8 PRIOR ART Fig la 1 7 1 PRIOR ART 3a3b a 01■W ■ '01■■ ■ '
    [11] 11. .k ■ . NLN k . 11 III III 1 Fig lb 2/8
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    同族专利:
    公开号 | 公开日
    SE538263C2|2016-04-19|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
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    SE1450809A|SE538263C2|2014-07-01|2014-07-01|Solar cell device and method for manufacture|SE1450809A| SE538263C2|2014-07-01|2014-07-01|Solar cell device and method for manufacture|
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