CN107994100A - 一种柔性单晶颗粒薄膜及其制备方法和应用 - Google Patents
一种柔性单晶颗粒薄膜及其制备方法和应用 Download PDFInfo
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Abstract
本发明公开了一种柔性单晶颗粒薄膜及其太阳能电池的制备方法，包括（1）利用印刷法在柔性衬底上依次制备阿拉伯树胶层、环氧树脂层，形成粘结剂层；（2）用静电转印法把单晶颗粒植入粘结剂层中；（3）先用研磨机磨掉表层的环氧树脂，使单晶颗粒表面裸露，再用等离子体刻蚀清洁裸露的单晶颗粒表面，得到柔性单晶颗粒薄膜；（4）在柔性单晶颗粒薄膜上制备缓冲层、窗口层以及电极层得到柔性单晶颗粒薄膜太阳能电池；本发明采用卷对卷法结合静电转印技术制备大面积柔性单晶颗粒薄膜的制备，克服现有技术中因导电材料在使用过程中容易被折断而影响柔性单晶颗粒薄膜的可靠性问题，在工业化生产方面具有明显的优势。
Description
技术领域
本发明涉及半导体光电材料与器件技术领域，更具体地，涉及一种柔性单晶颗粒薄膜，其备方法，以及在制备太阳能电池中的应用。
背景技术
太阳能是一种取之不尽、用之不竭的能量来源，太阳能电池提供了一种以最小的环境影响来产生电力的光电转换装置，具有环境又好无污染的特点，越来越受到人们的关注。低成本、高效率、易携带、可折叠、等问题是目前太阳能电池组件研究的主要方向。薄膜太阳能电池属于新一代太阳能电池，非晶/微晶硅、碲化镉（CdTe）和铜铟镓硒化合物（CIGS）是目前最常见的三种薄膜太阳能电池，按照衬底的种类可分为硬衬底和柔性衬底两大类，柔性衬底薄膜太阳能电池是指在柔性材料（如不锈钢、聚酯膜等）上制作的薄膜太阳能电池。与晶体硅片太阳能电池和硬衬底（如玻璃）薄膜太阳能电池相比，柔性薄膜太阳能电池具有可弯曲、不易破碎、质量轻等特点，逐渐成为近年来太阳能应用方面的重点。
现有技术中制作柔性薄膜太阳能电池的方法分为三个步骤：首先是卷对卷生产柔性薄膜太阳能电池的长电池片，然后利用切刀将长电池片分切成长方形的柔性电池单元，最后将柔性电池单元进行串联连接并制作于柔性基底上，经封装工艺后得到柔性薄膜太阳能电池。由于柔性薄膜太阳能柔性组件在使用过程中反复弯折卷曲，极易造成连接组件的材料折断，进而切断相邻薄膜太阳能电池单元的电连接，最终影响柔性薄膜太阳能电池的可靠性。
发明内容
本发明的目的在于提供一种采用卷对卷和静电转印技术的柔性单晶颗粒薄膜的制备方法，克服现有技术中因导电材料在使用过程中容易被折断而影响柔性单晶颗粒薄膜的可靠性。
本发明的目的还在于提供所述柔性单晶颗粒薄膜用于制备太阳能电池的方法。
本发明的柔性单晶颗粒薄膜的制备方法包括如下步骤：
（1）利用印刷法在柔性衬底上依次制备阿拉伯树胶层、环氧树脂层，形成粘结剂层；
（2）用静电转印法把单晶颗粒植入柔性衬底上的粘结剂层中；
（3）先用研磨机磨掉表层的环氧树脂，使单晶颗粒表面裸露，再用等离子体刻蚀清洁裸露的单晶颗粒表面，得到柔性单晶颗粒薄膜。
作为优选方案，步骤（1）中，阿拉伯树胶层、环氧树脂层的厚度分别为20～30μm和40～60μm，有利于单晶颗粒完全植入粘结剂层中；
所述柔性衬底选用聚酯薄膜（PET）、聚酰亚胺（PI）、不锈钢箔等。
步骤（2）中，选取50～85μm的单晶颗粒制备薄膜，可使薄膜表面更加平滑柔顺，在弯折卷曲过程中不易折断。
所述单晶颗粒是薄膜的有效成分，包括铜锌锡硫（CZTS）、铜锌锡硒（CZTSe）或铜锌锡硫硒（CZTSSe）单晶颗粒，本发明优选熔盐法制备单晶颗粒，可以控制单晶颗粒的组分，使每个单晶颗粒构成一个有效的电池单元，降低薄膜层的缺陷和界面杂质对器件性能的影响。
步骤（3）中，研磨的厚度为30～60μm，使单晶颗粒充分裸露而不致脱落，提高器件电学性能。
本发明得到的柔性单晶颗粒薄膜用于制备太阳能电池的方法，包括在柔性单晶颗粒薄膜上制备太阳能电池的缓冲层、窗口层以及电极层，得到柔性单晶颗粒薄膜太阳能电池。
本发明与现有技术相比，具有如下优点：
（1）现有技术利用卷对卷法难以控制单晶颗粒的分量，因而无法制备出大面积的柔性单晶颗粒薄膜；本发明利用静电转印技术，可控制单晶颗粒出料速度，因而成功获得大面积生产的柔性单晶颗粒薄膜。
（2）现有技术中单晶颗粒和薄膜的制备步骤同步进行，单晶颗粒质量难以控制，直接影响了太阳能电池的性能；本发明利用熔盐法制备得到的单晶颗粒作为薄膜的主要成分，每个单晶颗粒形成一个电池单元，可以实现有效控制单晶颗粒的组分，因而可以制备得到性能优异的太阳能电池。
（3）本发明中，单晶颗粒的制备过程和单晶颗粒薄膜的制备过程是分开的，可以有效控制单晶颗粒的质量，降低薄膜的缺陷和界面杂质对器件性能的影响，本发明在现有卷对卷法基础上结合静电转印技术可以实现大面积柔性单晶颗粒薄膜的制备，在工业化生产方面具有明显的优势。
附图说明
图1为本发明所述柔性单晶颗粒薄膜的制备流程示意图；
图2为本发明薄膜制备方法步骤（2）中所述单晶颗粒出料示意图；
图3为本发明薄膜制备方法步骤（2）中所述静电转印示意图。
具体实施方式
如图1所示，单晶颗粒置于供料筛（11）中，由供料筛控制单晶颗粒落在静电转印传送带（12）上的数量，当单晶颗粒传送至强静电场（13）时，由于电场力的作用使单晶颗粒植入到制备有粘结剂层的柔性衬底（14）上。
如图2所示，通过供料筛（11）控制单晶颗粒的出料速度，可以控制单晶颗粒薄膜的密度。
如图3所示，通过在静电转印传送带（12）和制备有粘结剂层的柔性衬底（14）之间加上强静电场（13），可以单晶颗粒植入到粘结剂层中形成单晶颗粒薄膜, 所述强静电场强度为2.5×106V/m~5×107V/m。
实施例1
（1）利用印刷法在PET柔性衬底上依次制备阿拉伯树胶层、环氧树脂层，形成粘结剂层；阿拉伯树胶层、环氧树脂层的厚度分别为20μm、60μm，
（2）用静电转印法把熔盐法制备的50μm的CZTS单晶颗粒植入粘结剂层中,静电场强度为2.5×106V/m；
（3）先用研磨机磨掉表层的环氧树脂，研磨的厚度为60μm，使单晶颗粒表面裸露，再用等离子体刻蚀清洁裸露的单晶颗粒表面，得到柔性单晶颗粒薄膜。
（4）在柔性单晶颗粒薄膜上制备太阳能电池的缓冲层、窗口层以及电极层，得到柔性单晶颗粒薄膜太阳能电池。
本实施例制备得到的Mo/CZTS/CdS/i-ZnO/AZO结构的单晶颗粒薄膜太阳能电池，其开路电压Voc=492mV，Jsc=26.7mA，FF=58.5%，电池的转换率达到6.8%。
对比例1
实验方法同实施例1，唯一不同的是不采用静电转印技术，结果表明：单晶颗粒无法转印到粘结剂层，无法制备出单晶颗粒薄膜，进而无法制备出柔性太阳能电池。
实施例2
（1）利用印刷法在PI柔性衬底上依次制备阿拉伯树胶层、环氧树脂层，形成粘结剂层；阿拉伯树胶层、环氧树脂层的厚度分别为30μm、40μm，
（2）用静电转印法把熔盐法制备的85μm的CZTSe单晶颗粒植入粘结剂层中，静电场强度为5×107V/m；
（3）先用研磨机磨掉表层的环氧树脂，研磨的厚度为40μm，使单晶颗粒表面裸露，再用等离子体刻蚀清洁裸露的单晶颗粒表面，得到柔性单晶颗粒薄膜。
（4）在柔性单晶颗粒薄膜上制备太阳能电池的缓冲层、窗口层以及电极层，得到柔性单晶颗粒薄膜太阳能电池。
本实施例制备得到的Mo/CZTSe/CdS/i-ZnO/AZO结构的单晶颗粒薄膜太阳能电池，其开路电压Voc=582mV，Jsc=21.7mA，FF=57.6%，电池的转换率达到6.2%。
对比例2
实验方法同实施例1，唯一不同的是不控制供料筛出料速度，结果表明：单晶颗粒无法均匀转印到粘结剂层中，导致无法制备出单晶颗粒分布均匀的柔性薄膜，进而无法制备单晶颗粒分布均匀的柔性单晶颗粒薄膜太阳能电池。
实施例3
（1）利用印刷法在不锈钢箔柔性衬底上依次制备阿拉伯树胶层、环氧树脂层，形成粘结剂层；阿拉伯树胶层、环氧树脂层的厚度分别为25μm、50μm，
（2）用静电转印法把熔盐法制备的65μm的CZTSSe单晶颗粒植入粘结剂层中，静电场强度为9×106V/m；
（3）先用研磨机磨掉表层的环氧树脂，研磨的厚度为50μm，使单晶颗粒表面裸露，再用等离子体刻蚀清洁裸露的单晶颗粒表面，得到柔性单晶颗粒薄膜。
（4）在柔性单晶颗粒薄膜上制备太阳能电池的缓冲层、窗口层以及电极层，得到柔性单晶颗粒薄膜太阳能电池。
本实施例制备得到的Mo/CZTSSe/CdS/i-ZnO/AZO结构的单晶颗粒薄膜太阳能电池，其开路电压Voc=542mV，Jsc=24.3mA，FF=64.5%，电池的转换率达到7.3%。
对比例3
实验方法同实施例1，唯一不同的是涂覆法制备粘结剂层，结果表明：粘结剂层厚薄不均，研磨后有些单晶颗粒无法裸露出来，进而无法形成有效的单晶颗粒薄膜电池，制备的太阳能电池组件效率低。
Claims (9)
1.一种柔性单晶颗粒薄膜的制备方法，其特征在于包括如下步骤：
（1）利用印刷法在柔性衬底上依次制备阿拉伯树胶层、环氧树脂层，形成粘结剂层；
（2）用静电转印法把单晶颗粒植入粘结剂层中；
（3）先用研磨机磨掉表层的环氧树脂，使单晶颗粒表面裸露，再用等离子体刻蚀清洁裸露的单晶颗粒表面，得到柔性单晶颗粒薄膜。
2.根据权利要求1所述的方法，其特征在于步骤（1）中，阿拉伯树胶层、环氧树脂层的厚度分别为20～30μm和40～60μm。
3.根据权利要求1或2所述的方法，其特征在于步骤（2）中，选取由熔盐法制备得到的50～85μm单晶颗粒。
4.根据权利要求3所述的方法，其特征在于步骤（2）中，所述静电转印包括：单晶颗粒置于供料筛（11）中，由供料筛控制单晶颗粒落在静电转印传送带（12）上的数量，当单晶颗粒传送至强静电场（13）时，电场力的作用使单晶颗粒植入到制备有粘结剂层的柔性衬底（14）上。
5.根据权利要求4所述的方法，其特征在于步骤（2）中，通过供料筛（11）控制单晶颗粒的出料速度来控制单晶颗粒薄膜的密度。
6.根据权利要求5所述的方法，其特征在于步骤（2）中，通过在静电转印传送带（12）和制备有粘结剂层的柔性衬底（14）之间加上静电场（13），使单晶颗粒植入到粘结剂层中形成单晶颗粒薄膜，所述静电场强度为2.5×106V/m~5×107V/m。
7.根据权利要求6所述的方法，其特征在于步骤（3）中，研磨的厚度为30～60μm。
8.权利要求1—7之一方法制备得到的柔性单晶颗粒薄膜。
9.权利要求8所述柔性单晶颗粒薄膜用于制备太阳能电池的方法，其特征在于是在柔性单晶颗粒薄膜上制备太阳能电池的缓冲层、窗口层以及电极层。
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| CN105633217A (zh) * | 2016-03-23 | 2016-06-01 | 岭南师范学院 | 一种微米级铜锗锌锡硫硒单晶颗粒的制备方法及其单晶颗粒和太阳能电池 |
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