Embodiments of the subject matter disclosed herein generally relate to a solar module and a method for making the solar module, and more particularly, to a thin-film solar module that has top-to-top connected perovskite solar cells.
With the growing global concern for fossil fuels usage and sustainability, renewable energy is evolving rapidly worldwide. Electricity generation is vital to modern economies and life. Currently, power generation accounts for almost 50% of the global greenhouse gas emissions. Decarbonizing the power sector, while meeting the growing electricity demand, is a major challenge for decades to come. Solar power using photovoltaics plays a critical role in addressing the energy challenge and it is expected to become the world's largest source of electricity.
Photovoltaic modules based on thin-film photoactive materials are usually realized by interconnecting the divided smaller single solar cells in series, on a common substrate, to maintain the module's efficiency. The single cells are defined by scribing the layers that form the cell: the front electrode, the transport layers, the absorber material, and the bottom electrode. Generally, these layers are deposited sequentially over the whole area of the module, using deposition techniques that can be scaled easily. Making use of the scribing processes, one can define the active areas of the single cells, the interconnections, and the geometrical fill-factor of the modules. These scribing processes are often referred to as P1, P2, and P3, where P1 is the scribe that defines the front electrode, P2 scribe etches the active layer, and P3 scribe isolates the bottom electrode and the interconnection between the cells.
The general fabrication process of a thin-film solar cell module 100 is depicted in
In this embodiment, the substrate 102 may be made of glass, the front electrode 104 may be made of a transparent conducting oxide, the front charge transport layer 106 may be made of CuSCN (i.e., a hole transport material), the active layer 110 may include any perovskite, the back charge transport layer may be made of SnO2 (i.e., an electron transport material), and the back electrode 116 may be made of a metal. In this architecture, the front and back charge transport layers are interchangeable. The charge transport layers include but are not limited to, semiconductors such as inorganic semiconductors, metal oxides, metal sulfides, organic semiconductors, polymers, and any electron or hole transport layers know in art.
The final module 100 having plural cells 120-I is illustrated in
Thus, there is a need for a new design of the solar cell module that is capable of converting solar energy into electrical energy at the same percentage or higher as the traditional modules while avoiding the formation of the recombination junction between the front and back charge transport layers.
According to an embodiment, there is a solar module for transforming solar energy into electrical energy, and the solar module includes a substrate and a pair of solar cells formed on the substrate next to each other and electrically connected in series to each other through a top common back electrode. A first solar cell of the pair has a pin configuration, and a second solar cell of the pair has a nip configuration. The pin configuration has hole and electron transport layers located in a reverse order relative to the nip configuration.
According to another embodiment, there is a solar module for transforming solar energy into electrical energy, and the solar module includes a substrate and plural pairs of solar cells formed on the substrate next to each other, each pair of solar cells being electrically connected in series to each other through a top common back electrode, and solar cells from two adjacent pairs being electrically connected in series to each other through a bottom common front electrode. Each pair of solar cells has one solar cell with a pin configuration and another cell with a nip configuration. The pin configuration has hole and electron transport layers located in a reverse order relative to the nip configuration.
According to yet another embodiment, there is a method for making a solar module for transforming solar energy into electrical energy. The method includes simultaneously forming a first solar cell and a second solar cell on a substrate, next to each other, and electrically connecting in series the first solar cell to the second solar cell through a top common back electrode. The first solar cell has a pin configuration, and the second solar cell has a nip configuration. The pin configuration has hole and electron transport layers located in a reverse order relative to the nip configuration.
For a more complete understanding of the present invention, reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:
The following description of the embodiments refers to the accompanying drawings. The same reference numbers in different drawings identify the same or similar elements. The following detailed description does not limit the invention. Instead, the scope of the invention is defined by the appended claims. The following embodiments are discussed, for simplicity, with regard to plural solar cells connected in series to form a module. However, the embodiments to be discussed next are not limited to solar cells, but may be applied to other semiconductor devices that use transport layers that sandwich a perovskite active material or other semiconductor absorber materials including, but not limited to, organic semiconductors and thin-film inorganic semiconductors.
Reference throughout the specification to “one embodiment” or “an embodiment” means that a particular feature, structure or characteristic described in connection with an embodiment is included in at least one embodiment of the subject matter disclosed. Thus, the appearance of the phrases “in one embodiment” or “in an embodiment” in various places throughout the specification is not necessarily referring to the same embodiment. Further, the particular features, structures or characteristics may be combined in any suitable manner in one or more embodiments.
According to an embodiment, a novel solar module that includes plural solar cells has the solar cells connected in a top-to-top manner instead of a top-to-bottom manner as the traditional devices do.
Despite the remarkable success with several industrial applications, the process illustrated in
To avoid the recombination junction shown in
According to an embodiment, a new concept for the fabrication of thin-film modules (for example, using perovskite photo-absorber) is introduced, which eliminates the issues associated with the conventional processing described above with regard to
According to this embodiment, when both pin and nip perovskite solar cells are brought together, they are configured as discussed next, to share the same back electrode, so that the two cells are connected in series. In this way, the metal contact is deposited only atop of the active area, via shadow masking, which avoids the formation of the perovskite/metal interface. Thanks to the alternating pin-nip configuration, electrons and holes recombine at the top metal contact (similarly to the single cell case), and for this reason this new configuration excludes the need of a recombination junction. By extending this approach to multiple cells, this embodiment discloses a new design to fabricate a thin-film perovskite module. In addition, the top-top approach reduces voltage building in comparison to top-bottom series connected cells for a given area (halves) and rather double the short circuit current.
The fabrication steps of the new process are described with regard to
Next, an active layer 510, for example, a perovskite layer, is deposited over the entire first transport layer 508-1, via 506, and the second transport layer 508-2, as shown in
Although
If the module 500 is desired to have more than two cells 520-1 and 520-2, then more pairs of such cells may be added, as illustrated in
With this novel design, the P1, P2, and P3 scribing processes are not required anymore. The P1 scribe can be substituted by the chemical etching, which can be obtained through a simple shadow mask. Also, the P2 process is completely eliminated since the perovskite layer is not patterned, and thanks to the micrometer diffusion-length of the charges, which is orders of magnitude inferior to the distance between the cells, the recombination event is avoided. Finally, the P3 can be substituted by simple masking of the deposition of the back electrode, preventing any contact between the perovskite and the metal, as shown in
The module 500 discussed above finds application in the field of renewable energies, particularly solar cells, and more specifically in the production of thin-film perovskite solar modules. The perovskite material absorber can be replaced by any suitably organic absorbers and polymer absorbers as well. The module 500 may be built to have any number of pairs of nip and pin solar cells.
A method manufacturing the module 500 is now discussed with regard to
The step of simultaneously forming the first and second solar cells includes forming the first front electrode 504-1 and forming the second front electrode 504-2 on the substrate so that the first and second front electrodes are separated by a gap, forming the first front charge transport layer 508-1 on the first front electrode and forming the second front charge transport layer 508-2 on the second front electrode, forming the active layer 510 on the first and second front charge transport layers, forming the first back charge transport layer 512-1 and forming the second back charge transport layer 512-2 on the active layer with a gap between the first and second back charge transport layers, and forming the top common back electrode 514 over the first and second back charge transport layers. The first front charge transport layer collects holes, the second front charge transport layer collects electrons, the first back charge transport layer collects electrons, and the second back charge transport layer collects holes so that the first solar cell has a pin configuration and the second solar cell has a nip configuration.
In one application, there is a via or gap between the first front charge transport layer and the second front charge transport layer. The substrate has a portion that extends beyond the first and second solar cells, and a portion of the top common back electrode extends directly above and touches the portion of the substrate. In this application or another one, there is no region where the first front and back charge transport layers, or the second front and back charge transport layers are in direct contact with each other. Also, in this or another application, there is no direct contact between the top common back electrode and the active layer.
The disclosed embodiments provide a top-to-top connected thin film solar module and method of manufacturing the same. It should be understood that this description is not intended to limit the invention. On the contrary, the embodiments are intended to cover alternatives, modifications and equivalents, which are included in the spirit and scope of the invention as defined by the appended claims. Further, in the detailed description of the embodiments, numerous specific details are set forth in order to provide a comprehensive understanding of the claimed invention. However, one skilled in the art would understand that various embodiments may be practiced without such specific details.
Although the features and elements of the present embodiments are described in the embodiments in particular combinations, each feature or element can be used alone without the other features and elements of the embodiments or in various combinations with or without other features and elements disclosed herein.
This written description uses examples of the subject matter disclosed to enable any person skilled in the art to practice the same, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the subject matter is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims.
This application claims priority to U.S. Provisional Patent Application No. 63/126,051, filed on Dec. 16, 2020, entitled “TOP-TO-TOP CONNECTED PEROVSKITE THIN FILM SOLAR MODULE: DESIGN, FABRICATION, AND METHODS,” and U.S. Provisional Patent Application No. 63/150,743, filed on Feb. 18, 2021, entitled “TOP-TO-TOP CONNECTED THIN SOLAR MODULE AND METHOD,” the disclosures of which are incorporated herein by reference in their entirety.
Filing Document | Filing Date | Country | Kind |
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PCT/IB2021/060655 | 11/17/2021 | WO |
Number | Date | Country | |
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63150743 | Feb 2021 | US | |
63126051 | Dec 2020 | US |