CN111048608B - Flexible malleable solar cell and method of manufacturing the same - Google Patents
Flexible malleable solar cell and method of manufacturing the same Download PDFInfo
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- H01L31/036—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by their semiconductor bodies characterised by their crystalline structure or particular orientation of the crystalline planes
- H01L31/0392—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by their semiconductor bodies characterised by their crystalline structure or particular orientation of the crystalline planes including thin films deposited on metallic or insulating substrates ; characterised by specific substrate materials or substrate features or by the presence of intermediate layers, e.g. barrier layers, on the substrate
- H01L31/03926—Semiconductor devices sensitive to infrared radiation, light, electromagnetic radiation of shorter wavelength or corpuscular radiation and specially adapted either for the conversion of the energy of such radiation into electrical energy or for the control of electrical energy by such radiation; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by their semiconductor bodies characterised by their crystalline structure or particular orientation of the crystalline planes including thin films deposited on metallic or insulating substrates ; characterised by specific substrate materials or substrate features or by the presence of intermediate layers, e.g. barrier layers, on the substrate comprising a flexible substrate
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- H01L31/05—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells
- H01L31/0504—Electrical interconnection means between PV cells inside the PV module, e.g. series connection of PV cells specially adapted for series or parallel connection of solar cells in a module
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Abstract
The present disclosure relates to a flexible malleable solar cell and a method of manufacturing the same. The battery comprises a plurality of battery cells, a plurality of first electrode connections, a plurality of second electrode connections, a plurality of first interconnect lines, a plurality of second interconnect lines, an encapsulation layer, and a malleable substrate for carrying the battery; the adjacent first electrode connecting parts and the second electrode connecting parts are connected together through corresponding second interconnecting wires; each battery unit is positioned above the corresponding second electrode connecting part and used for converting the received light energy into electric energy; the second electrode of each battery cell is connected to a second electrode connection part located below the battery cell, and the first electrode is connected to an adjacent first electrode connection part through a corresponding first interconnection line; the encapsulation layer is used for encapsulating the battery. The battery and the manufacturing method thereof have the advantages that the manufacturing process is simple, the manufactured battery is good in flexibility and extensibility, can still stably work when being stressed and deformed, the energy conversion efficiency is high, and the application range is wide.
Description
Technical Field
The present disclosure relates to the field of flexible electronics, and more particularly, to an extensible solar cell and a method for manufacturing the same.
Background
As flexible electronic technology has achieved many research results and industrial success cases in the fields of sensing, displaying, etc., it is known that flexible power sources (such as batteries) have become significant shortboards that restrict further development of flexible electronic technology. The extensibility, reliability and device efficiency of the flexible energy source module are obviously lower than those of functional modules such as flexible sensing, flexible display and flexible control.
The current flexible energy technology mainly has the following principles, namely, the flexible energy storage technology comprises a flexible battery and a flexible super capacitor; and the other is flexible energy collection technology, including energy collection modes such as wireless radio frequency, photovoltaic, thermoelectric, piezoelectric, triboelectric and biological energy batteries. The photovoltaic technology is also called as a solar cell technology, is a green, environment-friendly and sustainable energy collection mode, and is suitable for supplying energy to wearable electronic equipment. The current flexible solar cell technology can be divided into three types, one is a thin-film solar cell technology based on amorphous silicon, copper indium gallium selenide, cadmium telluride and other inorganic materials, the other is an organic solar cell based on polymer, and the other is a perovskite and dye-sensitized solar cell and quantum dot solar cell and other novel solar cell technologies. However, in the related art, the battery provided by the flexible solar cell technology is difficult to meet the requirements of users for flexibility and extensibility, which is a technical problem to be solved at present.
Disclosure of Invention
In view of the above, the present disclosure proposes a flexible malleable solar cell and a method of manufacturing the same.
According to an aspect of the present disclosure, there is provided a flexible malleable solar cell, the cell comprising: a plurality of battery cells, a plurality of first electrode connections, a plurality of second electrode connections, a plurality of first interconnect lines, a plurality of second interconnect lines, an encapsulation layer, and a malleable substrate,
the plurality of first electrode connecting parts and the plurality of second electrode connecting parts are placed above the extensible substrate, the first electrode connecting parts and the second electrode connecting parts are arranged in an array mode, the first electrode connecting parts and the second electrode connecting parts in the same row or the same column are alternately placed, and intervals exist among the plurality of first electrode connecting parts, among the plurality of second electrode connecting parts, and among the first electrode connecting parts and the second electrode connecting parts;
the adjacent first electrode connecting parts and the second electrode connecting parts are connected together through corresponding second interconnecting wires;
each battery unit is positioned above the corresponding second electrode connecting part and used for converting the received light energy into electric energy;
each battery cell includes a first electrode and a second electrode, the second electrode of each battery cell is connected to a second electrode connection part located under the battery cell, and the first electrode is connected to an adjacent first electrode connection part through a corresponding first interconnection line;
the packaging layer is made of a transparent material and is used for packaging the battery units, the first electrode connecting parts, the second electrode connecting parts, the first interconnection lines and the second interconnection lines onto the extensible substrate.
In one possible implementation, the battery further includes at least one of a first insulating layer and a second insulating layer:
the first insulating layer covers the plurality of first electrode connection parts, the plurality of second electrode connection parts and the plurality of second interconnection lines;
the second insulating layer located under the plurality of first electrode connection parts, the plurality of second electrode connection parts, and the plurality of second interconnection lines,
wherein the second interconnect line has a shape of malleable shape, a first portion of the first insulating layer overlying the second interconnect line has a shape that is the same as the shape of the second interconnect line that the first portion overlies, and a second portion of the second insulating layer underlying the second interconnect line has a shape that is the same as the shape of the second interconnect line overlying the second portion.
In one possible implementation, the first electrode and the second electrode are coplanar electrodes or non-coplanar electrodes,
when the first electrode and the second electrode are coplanar electrodes, the first electrode and the second electrode are both arranged on one surface of the battery unit away from the second electrode connecting part, the second electrode is connected with the second electrode connecting part through an interconnecting wire,
when the first electrode and the second electrode are different-surface electrodes, the first electrode is arranged on one surface of the battery unit far away from the second electrode connecting part, the second electrode is arranged on one surface of the battery unit close to the second electrode connecting part, and the second electrode is in contact connection with the second electrode connecting part.
In one possible implementation, the battery further comprises a reinforcing layer,
the reinforcing layer includes a plurality of reinforcing parts, each reinforcing part is disposed at an electrode connection region corresponding to each battery cell, the electrode connection region including at least one of: the area of the first electrode and the first electrode connecting part connected with the first electrode, the area of the second electrode and the second electrode connecting part connected with the second electrode,
the reinforcing part at least covers the first interconnection line and/or the interconnection line for connecting the second electrode and the second electrode connecting part, and the reinforcing part is made of a transparent material.
In one possible implementation, the battery further includes a first output terminal connected to the first electrode connection part through the second interconnection line, and a second output terminal connected to the second electrode connection part through the corresponding point second interconnection line,
the first output end and the second output end are used for outputting the electric energy.
In one possible implementation manner, the battery units in the plurality of battery units are connected in series and/or parallel,
wherein the connection between the first electrode connection part and the second electrode connection part corresponds to the connection manner between the battery cells.
According to another aspect of the present disclosure, there is provided a method for manufacturing a flexible and malleable solar cell, characterized in that the method is used for manufacturing the above flexible and malleable solar cell, the method comprising:
depositing a conductive film on a hard substrate, and processing the conductive film to form a plurality of first electrode connecting parts, a plurality of second electrode connecting parts and a plurality of second interconnecting lines, wherein the first electrode connecting parts and the second electrode connecting parts are arranged in an array manner, and the first electrode connecting parts and the second electrode connecting parts in the same row or the same column are alternately arranged, and intervals exist among the plurality of first electrode connecting parts, among the plurality of second electrode connecting parts, and among the first electrode connecting parts and the second electrode connecting parts;
transferring the prepared plurality of first electrode connections, the plurality of second electrode connections and the plurality of second interconnect lines onto a pre-prepared malleable substrate;
respectively placing a plurality of battery units on the corresponding second electrode connecting parts, and realizing the connection between the second electrode of each battery unit and the lower second electrode connecting part;
enabling connection between the first electrode of each battery cell and the adjacent first electrode connection part using a plurality of first interconnection lines;
and packaging the plurality of battery units, the plurality of first electrode connecting parts, the plurality of second electrode connecting parts, the plurality of first interconnecting lines and the plurality of second interconnecting lines by using a transparent packaging material to obtain the flexible extensible solar battery.
In one possible implementation, depositing a conductive film on a rigid substrate, and processing the conductive film to form a plurality of first electrode connection portions, a plurality of second electrode connection portions, and a plurality of second interconnection lines includes:
generating a sacrificial layer on the hard substrate, and spin-coating an insulating material on the sacrificial layer to form a second insulating layer to be processed;
depositing a conductive film on the second insulating layer to be processed, and processing the conductive film to form a plurality of first electrode connecting parts, a plurality of second electrode connecting parts and a plurality of second interconnecting wires;
spin-coating an insulating material on the plurality of first electrode connecting parts, the plurality of second interconnecting lines and the exposed second insulating layer to be processed to form a first insulating layer to be processed;
processing the first insulating layer to be processed and the second insulating layer to be processed to obtain a first insulating layer and a second insulating layer,
wherein the second interconnect line has a shape of malleable shape, a first portion of the first insulating layer overlying the second interconnect line has a shape that is the same as the shape of the second interconnect line that the first portion overlies, and a second portion of the second insulating layer underlying the second interconnect line has a shape that is the same as the shape of the second interconnect line overlying the second portion.
In one possible implementation, the first electrode and the second electrode are coplanar electrodes or non-coplanar electrodes,
when the first electrode and the second electrode are coplanar electrodes, the first electrode and the second electrode are both arranged on one surface of the battery unit away from the second electrode connecting part, the second electrode is connected with the second electrode connecting part through an interconnecting wire,
when the first electrode and the second electrode are different-surface electrodes, the first electrode is arranged on one surface of the battery unit far away from the second electrode connecting part, the second electrode is arranged on one surface of the battery unit close to the second electrode connecting part, and the second electrode is in contact connection with the second electrode connecting part.
In one possible implementation, the method further includes:
generating a reinforcing part at an electrode connection region corresponding to each battery cell using a transparent reinforcing material before packaging to obtain a reinforcing layer composed of a plurality of reinforcing parts,
wherein the electrode connection region comprises at least one of: the area of the first electrode and the first electrode connecting part connected with the first electrode, the area of the second electrode and the second electrode connecting part connected with the second electrode,
wherein the reinforcement part covers at least the first interconnection line and/or an interconnection line for connecting the second electrode with the second electrode connection part.
In one possible implementation, depositing a conductive film on a rigid substrate, and processing the conductive film to form a plurality of first electrode connection portions, a plurality of second electrode connection portions, and a plurality of second interconnection lines includes:
depositing a conductive film on a rigid substrate, and processing the conductive film to form a plurality of first electrode connection parts, a plurality of second interconnection lines, a first output terminal and a second output terminal, the first output terminal being connected to the first electrode connection parts through the second interconnection lines, the second output terminal being connected to the second electrode connection parts through corresponding point second interconnection lines,
wherein the first output terminal and the second output terminal are used for outputting the electric energy.
According to the flexible extensible solar cell and the manufacturing method thereof provided by the embodiment of the disclosure, the process of manufacturing the cell is simple, the manufactured cell is good in flexibility and extensibility, can still continue to stably work to generate electric energy when being subjected to large deformation such as bending, stretching and compressing under stress, is high in energy conversion efficiency, can be used as a power supply of wearable equipment, and is wide in application range.
Other features and aspects of the present disclosure will become apparent from the following detailed description of exemplary embodiments, which proceeds with reference to the accompanying drawings.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate exemplary embodiments, features, and aspects of the disclosure and, together with the description, serve to explain the principles of the disclosure.
Fig. 1 shows a cross-sectional view of a flexible malleable solar cell, in accordance with an embodiment of the present disclosure.
Fig. 2 shows a schematic top view of a flexible malleable solar cell, in accordance with an embodiment of the disclosure.
Fig. 3 shows a flow diagram of a method of manufacturing a flexible malleable solar cell, in accordance with an embodiment of the disclosure.
Detailed Description
Various exemplary embodiments, features and aspects of the present disclosure will be described in detail below with reference to the accompanying drawings. In the drawings, like reference numbers can indicate functionally identical or similar elements. While the various aspects of the embodiments are presented in drawings, the drawings are not necessarily drawn to scale unless specifically indicated.
The word "exemplary" is used exclusively herein to mean "serving as an example, embodiment, or illustration. Any embodiment described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments.
Furthermore, in the following detailed description, numerous specific details are set forth in order to provide a better understanding of the present disclosure. It will be understood by those skilled in the art that the present disclosure may be practiced without some of these specific details. In some instances, methods, means, elements and circuits that are well known to those skilled in the art have not been described in detail so as not to obscure the present disclosure.
Fig. 1 shows a cross-sectional view of a flexible malleable solar cell in accordance with an embodiment of the disclosure, and fig. 2 shows a schematic top view of a flexible malleable solar cell in accordance with an embodiment of the disclosure. As shown in fig. 1, 2, the battery includes a plurality of battery cells 2, a plurality of first electrode connections 3, a plurality of second electrode connections 4, a plurality of first interconnect lines 7, a plurality of second interconnect lines 10, an encapsulation layer 1, and a malleable substrate 9. The shape of the second interconnect lines 10 is a malleable shape.
The plurality of first electrode connecting portions 3 and the plurality of second electrode connecting portions 4 are placed above the extensible substrate 9, the first electrode connecting portions 3 and the second electrode connecting portions 4 are arranged in an array manner, the first electrode connecting portions 3 and the second electrode connecting portions 4 in the same row or the same column are alternately placed, and intervals exist among the plurality of first electrode connecting portions 3, among the plurality of second electrode connecting portions 4, and among the first electrode connecting portions 3 and the second electrode connecting portions 4.
The adjacent first electrode connecting portions 3 and second electrode connecting portions 4 are connected together by corresponding second interconnecting lines 10.
Each battery cell 2 is located above the corresponding second electrode connection part 4 for converting received light energy into electrical energy.
Each battery cell 2 includes a first electrode and a second electrode (not shown in the drawings), the second electrode of each battery cell 2 is connected to a second electrode connection part 4 located under the battery cell 2, and the first electrode is connected to an adjacent first electrode connection part 3 through a corresponding first interconnection line 7.
The encapsulation layer 1 is a transparent material for encapsulating the plurality of battery cells 2, the plurality of first electrode connections 3, the plurality of second electrode connections 4, the plurality of first interconnect lines 7, the plurality of second interconnect lines 10 onto the malleable substrate 9.
In this embodiment, the thickness of the plurality of first electrode connection parts and the plurality of second electrode connection parts is uniform, and may be 10mm to 200 nm. The thickness of the second interconnection line may be 10mm-200 nm. The length of the first interconnection line may be 1mm-5 nm. The area of the occupied second electrode connection part of the battery cell may be 1mm2-4mm2The area of the second electrode connection part occupied by the battery cell may be square, rectangular, etc., for example, the area occupied by the battery cell may be an area of 1mm × 1mm, an area of 1mm × 2mm, the thickness of the extensible substrate may be 1 μm to 10 μm, the entire battery may be in the form of a sheet of square, rectangular, etc., and when the battery is rectangular or square, the area of the surface on which the length and width of the battery are located may be 2cm2-25mm2The length and width of the battery can be 2cm-5 cm.
In this embodiment, the plurality of battery units may be arranged in a rectangular or square array as shown in fig. 2, or may be arranged in an array in a polygonal shape such as a triangle or a hexagon, or the plurality of battery units may be arranged in an array in an irregular shape, and a person skilled in the art may set the arrangement mode and the shape of the plurality of battery units according to the connection requirement between the plurality of battery units, the overall shape of the battery, and the like, which is not limited in this disclosure. The material of the battery unit can be monocrystalline silicon so as to ensure that the battery has higher energy conversion efficiency. The plurality of battery cells may be prepared on a single crystal silicon wafer, and then the wafer dicing machine may be used to dice the plurality of battery cells so that the plurality of battery cells are separated into independent units to obtain a plurality of required battery cells.
In this embodiment, the material of the encapsulation layer and the malleable substrate may be Polydimethylsiloxane (PDMS), silicone (such as Silbine, Ecoflex, Dragonskin), epoxy resin, or other polymer materials with low modulus, softness, and high light transmittance. For example, the existing silicone adhesive materials have good Silbine flexibility and Dragonskin tensile strength, the Ecoflex performance is between the Silbine and Dragonskin, and the materials of the encapsulation layer and the extensible substrate can be selected according to actual needs. Wherein the material of the extensible substrate may also be a fabric having flexibility and extensibility. The first electrode connection portions, the second electrode connection portions, and the second interconnection lines may be made of a metal material, a carbon-based material (e.g., graphene, carbon nanotubes, etc.), or the like having a good conductive property. Such as gold, copper, silver nanowires, silver nanoparticles, carbon nanotubes, graphene, and the like. Among them, gold is particularly preferable because of its good conductivity and stability, and gold can be preferably used.
In this embodiment, the first electrode connection part and the second electrode connection part may be provided with different physical properties in order to distinguish the first electrode connection part from the second electrode connection part. For example, as shown in fig. 2, the first electrode connection part may be provided in a circular shape and the second electrode connection part may be provided in a square shape.
In this embodiment, when the material of the extensible substrate is a non-adhesive material such as a fabric, an adhesive layer may be added or prepared on the extensible substrate in advance, so that the plurality of first electrode connection portions, the plurality of second electrode connection portions, and the plurality of second interconnection lines (or the first insulating layer, the plurality of first electrode connection portions, the plurality of second electrode connection portions, and the plurality of second interconnection lines and the second insulating layer) may be fixedly connected to the extensible substrate by the adhesive effect of the adhesive layer. The material of the bonding layer can be a material with viscosity, ductility and flexibility, such as a photo-curing adhesive, a thermosetting or thermoplastic hot melt adhesive and the like, and the thickness of the bonding layer can be 1-20 μm. The present disclosure is not so limited.
In this embodiment, the first interconnection line may be prepared by gold wire ball bonding, printing (e.g., 3D printing), or other techniques, so as to electrically connect the first electrode and the first electrode connection portion. For example, the first interconnection line may be printed between the first electrode and the first electrode connection portion by using a printing technique using conductive ink as a raw material, where the conductive ink may be ink having a quick-drying characteristic, and the printing technique may be a micro 3D printing technique. The conductive ink may include a silver nanowire solution, a silver nanoparticle solution, a carbon nanotube solution, a graphene solution, and the like. The preparation mode of the first interconnection line can be set by a person skilled in the art according to actual needs, and the disclosure does not limit this.
In the present embodiment, since the plurality of first interconnection lines, the plurality of second interconnection lines, the encapsulation layer, and the malleable substrate all have certain flexibility and malleability, the flexibility and malleability of the entire battery can be improved. And due to its possessed characteristics, the battery provided by the present disclosure can be applied to objects, living bodies, and the like and is suitable for various surface shapes. For example, the battery may be applied to a portion having a cylindrical surface, a prismatic surface, or the like, such as a battery used as a device worn on the trunk, limbs, or the like of a human body; it can also be applied to non-developable surfaces, such as batteries of devices worn on joints of the human body.
The flexible extensible solar cell provided by the embodiment of the disclosure has good flexibility and extensibility, can still continue to stably work to generate electric energy when being stressed to generate large deformation such as bending, stretching and compressing, has high energy conversion efficiency, can be used as a power supply of wearable equipment, and has a wide application range.
In one possible implementation, the battery may further include at least one of the first insulating layer 6 and the second insulating layer 5.
The first insulating layer 6 covers the plurality of first electrode connection parts 3, the plurality of second electrode connection parts 4, and the plurality of second interconnection lines 10.
The second insulating layer 5 is positioned below the plurality of first electrode connection parts 3, the plurality of second electrode connection parts 4, and the plurality of second interconnection lines 10.
Wherein the shape of the second interconnect line is a malleable shape, the shape of a first portion of the first insulating layer 6 overlying the second interconnect line 10 is the same as the shape of the second interconnect line 10 the first portion overlies, and the shape of a second portion of the second insulating layer 5 underlying the second interconnect line 10 is the same as the shape of the second interconnect line 10 overlying the second portion.
In this implementation, the material of the first insulating layer and the second insulating layer may be a polymer material with relatively moderate modulus (e.g., higher modulus than that of the encapsulation layer and the stretchable substrate) and excellent dielectric property, such as Polyimide (PI), Polyethylene terephthalate (PET), Polyethylene naphthalate (PEN), and the like, and the material of the first insulating layer and the second insulating layer may be the same or different, which is not limited in this disclosure.
In this implementation, the malleable shape of the second interconnect line may be an "S" -shaped, "zig-zag," serpentine, or other malleable shape. Therefore, when the battery is stressed to be bent, stretched, compressed and the like, and the structure of the second interconnecting line is not damaged, the battery can work normally, and electric energy supply is continuously carried out.
In this implementation, the size of the first insulating layer and the second insulating layer may be the same as the size of the second interconnect line covered by the first insulating layer or may be slightly larger than the size of the second interconnect line. The shape of the first insulating layer and the second insulating layer and the shape of the second interconnection line covered by the first insulating layer may be identical or substantially similar. In this way, the first insulating layer and the second insulating layer have an insulating effect, and at the same time, the deformation limit and reliability of the battery under stress deformation can be enhanced by increasing the tensile strength of the functional layer (the portion that performs the battery function, that is, the plurality of battery cells, the plurality of first electrode connecting portions, the plurality of second electrode connecting portions, the plurality of first interconnecting lines, and the plurality of second interconnecting lines in the battery), without limiting the stress deformation capability thereof.
In one possible implementation, the first electrode and the second electrode are coplanar electrodes or non-coplanar electrodes.
When the first electrode and the second electrode are coplanar electrodes, the first electrode and the second electrode are both arranged on one surface of the battery unit away from the second electrode connecting part, and the second electrode is connected with the second electrode connecting part through an interconnecting wire.
In this implementation manner, if the first electrode and the second electrode are coplanar electrodes, an interconnection line for connecting the second electrode and the second electrode connection portion may be prepared by using technologies such as gold wire ball bonding, printing (e.g., 3D printing), and the like (similar to the preparation manner of the first interconnection line), so as to achieve electrical conduction between the second electrode and the second electrode connection portion. Meanwhile, in order to secure the fixed connection of the battery cell and the second electrode connection part, the battery cell may be fixed to the second electrode connection part by an adhesive material having adhesive properties. For example, the interconnection line may be printed between the second electrode and the second electrode connection portion by using a printing technique using conductive ink as a raw material, where the conductive ink may be ink having a quick-drying characteristic, and the printing technique may be a micro 3D printing technique. The preparation method of the interconnection line between the second electrode and the second electrode connecting portion can be set by those skilled in the art according to actual needs, and the disclosure does not limit this.
When the first electrode and the second electrode are different-surface electrodes, the first electrode is arranged on one surface of the battery unit far away from the second electrode connecting part, the second electrode is arranged on one surface of the battery unit close to the second electrode connecting part, and the second electrode is in contact connection with the second electrode connecting part.
In this implementation manner, if the first electrode and the second electrode are different-surface electrodes and the second electrode connecting portion are in direct conductive contact with each other, the second electrode and the second electrode connecting portion can be directly connected together by using a material having conductive and adhesive properties, such as conductive silver paste, and the battery cell and the second electrode connecting portion can be fixedly connected.
In one possible implementation, the battery further comprises a reinforcement layer 8. The reinforcing layer 8 includes a plurality of reinforcing parts, each of which is provided to an electrode connection region corresponding to each of the battery cells, the electrode connection region including at least one of: the first electrode and the area where the first electrode connecting part is connected, and the second electrode and the area where the second electrode connecting part is connected. The reinforcing part at least covers the first interconnection line and/or the interconnection line for connecting the second electrode and the second electrode connecting part, and the reinforcing part is made of a transparent material.
In this implementation, the material of the reinforcement layer may be a transparent polymer with a relatively high modulus (e.g., a modulus higher than that of the first insulation layer), such as an epoxy resin, a light-curable adhesive, etc., which is not limited by the present disclosure.
Through the arrangement of the enhancement layer, the stability of the first interconnection line and/or the interconnection line for connecting the second electrode with the second electrode connecting part can be provided, and when the battery is deformed under stress, the reliability and the stability of the connection between the battery unit in the battery and the first electrode connecting part and/or the second electrode connecting part can be protected due to the existence of the enhancement layer.
In a possible implementation, the battery may further include a first output terminal 11 and a second output terminal 12. The first output terminal 11 is connected to the first electrode connection part 3 through a second interconnection line 10, and the second output terminal 12 is connected to the second electrode connection part 4 through a corresponding point second interconnection line 10. The first output terminal 11 and the second output terminal 12 are used for outputting the electric energy.
In this implementation, the first output and the second output may be disposed in close proximity on the same side of the battery (as shown in fig. 2). The first output terminal and the second output terminal may be disposed at other positions of the battery, which is not limited by the present disclosure.
In one possible implementation manner, the battery units in the plurality of battery units are connected in series and/or parallel,
wherein the connection between the first electrode connection part and the second electrode connection part corresponds to the connection manner between the battery cells.
In this implementation, all of the battery cells may be connected in series, all of the battery cells may be connected in parallel, some of the battery cells may be connected in series and then connected in parallel (as shown in fig. 2), and some of the battery cells may be connected in parallel and then connected in series. In order to ensure the series and/or parallel connection relationship of the battery cells, the connection between the first connection part and the second connection part corresponding to the battery cells is also consistent with the series and/or parallel connection relationship of the battery cells.
Wherein the parallel connection of the battery cells can adjust the operating current of the entire battery, and the series connection of the battery cells can adjust the operating voltage of the entire battery. The number of the battery units in the battery, the number of the parallel connection and the series connection, and the proportion can be set by those skilled in the art according to actual needs, and the disclosure does not limit the number.
For example, as shown in fig. 2, if m × n units are connected in series by n units and then the m groups of series-connected units are connected in parallel, the working current I of the scalable solar cell is obtainedworkOperating voltage VworkAnd operating power PworkThe calculation can be performed by equations (1) to (3).
Iwork＝m×I0(1)
Vwork＝n×V0(2)
Pwork＝m×n×P0(3)
Wherein, I0And V0Respectively the output current and the output voltage, P, of the battery unit 20Is the output power of the battery unit 2.
Fig. 3 shows a flow chart of a method of manufacturing a flexible malleable solar cell according to an embodiment of the present disclosure, as shown in fig. 3, the method includes steps S11 to S15 for manufacturing the above-described flexible malleable solar cell.
In step S11, a conductive film is deposited on a hard substrate and processed to form a plurality of first electrode connection portions, a plurality of second electrode connection portions, and a plurality of second interconnection lines. The first electrode connecting parts and the second electrode connecting parts are arranged in an array mode, the first electrode connecting parts and the second electrode connecting parts in the same row or the same column are alternately arranged, and intervals exist among the plurality of first electrode connecting parts, among the plurality of second electrode connecting parts and among the first electrode connecting parts and the second electrode connecting parts.
In this embodiment, the material of the hard substrate may be a hard rigid material such as a silicon wafer or a glass plate. The hard substrate needs to have the characteristics of no reaction with the conductive film and the sacrificial layer described below, hard texture and the like so as to meet the requirements of subsequent etching, transferring and other treatment.
In this embodiment, the deposition preparation of the conductive film can be performed by using physical and chemical vapor phase methods, molecular beam epitaxy methods, spin coating or spray coating methods, electroplating methods, evaporation methods, and the like. For example, magnetron sputtering in a physical vapor deposition method, electron beam evaporation in vacuum evaporation plating, and the like are used.
In one possible implementation, step S11 may include:
generating a sacrificial layer on the hard substrate, and spin-coating an insulating material on the sacrificial layer to form a second insulating layer to be processed;
depositing a conductive film on the second insulating layer to be processed, and processing the conductive film to form a plurality of first electrode connecting parts, a plurality of second electrode connecting parts and a plurality of second interconnecting wires;
spin-coating an insulating material on the plurality of first electrode connecting parts, the plurality of second interconnecting lines and the exposed second insulating layer to be processed to form a first insulating layer to be processed;
processing the first insulating layer to be processed and the second insulating layer to be processed to obtain a first insulating layer and a second insulating layer,
wherein the shape of a first part of the first insulating layer covering the second interconnection line is the same as the shape of the second interconnection line covered by the first part, and the shape of a second part of the second insulating layer below the second interconnection line is the same as the shape of the second interconnection line above the second part.
In this implementation, the material of the sacrificial layer may be a material that is easily etched by machining, such as polymethyl methacrylate (PMMA), and the disclosure is not limited thereto.
In this implementation manner, the conductive thin film may be etched by dry etching, wet etching, and other etching manners to obtain a plurality of first electrode connection portions, a plurality of second electrode connection portions, and a plurality of second interconnection lines, and the first insulating layer to be processed and the second insulating layer to be processed may be etched to obtain the first insulating layer and the second insulating layer. For example, the conductive thin film, the first insulating layer to be processed, and the second insulating layer to be processed are etched by photolithography etching or laser etching. For example, taking the second insulating layer as an example, a photoresist type polymer (such as photoresist type polyimide) is selected as a material of the second insulating portion, the material is spin-coated on the sacrificial layer, the material is directly patterned by photolithography and development, and then the material is cured to form the second insulating layer with a designed pattern. Selecting a non-photoetching polymer as a material of the second insulating layer, spin-coating and curing the material on the sacrificial layer to obtain a second insulating layer to be processed, evaporating metal such as copper or chromium on the second insulating layer to be processed, patterning the metal layer by photoetching to be used as a mask of the second insulating layer to be processed, and realizing the patterning of the second insulating layer to be processed by Reactive Ion Etching (RIE) to form the second insulating layer with a designed pattern. It should be noted that, a person skilled in the art may set the etching manner to be used according to actual needs, and the disclosure does not limit this.
In this implementation, the first insulating layer, the plurality of first electrode connections, the plurality of second interconnect lines, and the second insulating layer may be transferred to the ductile substrate after the sacrificial layer is etched away by an etching method such as dry etching, wet etching, or the like before the transferring. For example, when the material of the sacrificial layer is PMMA, the sacrificial layer can be etched away by using acetone.
In step S12, the prepared plurality of first electrode connections, the plurality of second electrode connections, and the plurality of second interconnect lines are transferred onto a pre-prepared malleable substrate.
In this embodiment, the plurality of first electrode connections, the plurality of second electrode connections, and the plurality of second interconnecting lines (or the first insulating layer, the plurality of first electrode connections, the plurality of second electrode connections, and the plurality of second interconnecting lines and the second insulating layer) may be transferred to the malleable substrate using a transfer technique such as transfer. The transfer can be performed by means of stamp transfer, and can also be performed by means of a water-soluble adhesive tape, a heat release adhesive tape, or the like.
In this embodiment, the ductile substrate may be prepared by methods such as mold casting, etching, and the like, which are not limited by this disclosure. When the material of the extensible substrate is a material having no adhesiveness, such as a fabric, an adhesive layer may be added or prepared on the extensible substrate in advance, so that the plurality of first electrode connection portions, the plurality of second electrode connection portions, and the plurality of second interconnection lines (or the first insulating layer, the plurality of first electrode connection portions, the plurality of second electrode connection portions, and the plurality of second interconnection lines and the second insulating layer) may be fixedly connected to the extensible substrate by an adhesive effect of the adhesive layer. The material of the adhesive layer may be a material with viscosity, ductility and flexibility, such as a photo-curing adhesive, a thermosetting or thermoplastic hot melt adhesive, and the disclosure is not limited thereto.
In step S13, a plurality of battery cells are respectively placed on the corresponding second electrode connection parts, and the connection of the second electrode of each battery cell to the lower second electrode connection part is accomplished.
In the present embodiment, the battery cell may be placed on the second electrode connection part using a chip mounter or the like, which is not limited by the present disclosure.
In step S14, the connection between the first electrode of each battery cell and the adjacent first electrode connection part is achieved using a plurality of first interconnection lines.
In this embodiment, the first interconnection line may be prepared by gold wire ball bonding, printing (e.g., 3D printing), or other techniques, so as to electrically connect the first electrode and the first electrode connection portion. For example, the first interconnection line may be printed between the first electrode and the first electrode connection portion by using a printing technique using conductive ink as a raw material, where the conductive ink may be ink having a quick-drying characteristic, and the printing technique may be a micro 3D printing technique. The ink jet printer based on the principle of electronic jet printing and the superfine nozzle are utilized to spray conductive ink by the superfine nozzle, the solvent of the ink is quickly volatilized in the air, and the conductive ink after the solvent is volatilized forms an interconnecting line between the second electrode and the connecting part of the second electrode. The preparation mode of the first interconnection line can be set by a person skilled in the art according to actual needs, and the disclosure does not limit this.
In one possible implementation, each battery cell includes a first electrode and a second electrode, and the first electrode and the second electrode are coplanar electrodes or non-coplanar electrodes.
When the first electrode and the second electrode are coplanar electrodes, the first electrode and the second electrode are both arranged on one surface of the battery unit away from the second electrode connecting part, and the second electrode is connected with the second electrode connecting part through an interconnecting wire. In step S13, an interconnection line for connecting the second electrode and the second electrode connection portion may be prepared by using techniques such as gold wire ball bonding, printing (e.g., 3D printing), and the like, so as to achieve electrical conduction between the second electrode and the second electrode connection portion. Meanwhile, in order to secure the fixed connection of the battery cell and the second electrode connection part, the battery cell may be fixed to the second electrode connection part by an adhesive material having adhesive properties. For example, the interconnection line may be printed between the second electrode and the second electrode connection portion by using a printing technique using conductive ink as a raw material, where the conductive ink may be ink having a quick-drying characteristic, and the printing technique may be a micro 3D printing technique. The ink jet printer based on the principle of electronic jet printing and the superfine nozzle are utilized to spray conductive ink by the superfine nozzle, the solvent of the ink is quickly volatilized in the air, and the conductive ink after the solvent is volatilized forms an interconnecting line between the second electrode and the connecting part of the second electrode. The preparation method of the interconnection line between the second electrode and the second electrode connecting portion can be set by those skilled in the art according to actual needs, and the disclosure does not limit this.
When the first electrode and the second electrode are different-surface electrodes, the first electrode is arranged on one surface of the battery unit far away from the second electrode connecting part, the second electrode is arranged on one surface of the battery unit close to the second electrode connecting part, and the second electrode is in contact connection with the second electrode connecting part. If the first electrode and the second electrode are different-surface electrodes and the second electrode can be in direct conductive contact with the second electrode connecting part, in step S13, the second electrode and the second electrode connecting part can be directly connected together by using conductive silver paste or other materials with conductive and adhesive properties, and the battery cell and the second electrode connecting part can be fixedly connected.
In one possible implementation, the method may further include: before packaging, a reinforcing portion is formed at an electrode connection region corresponding to each battery cell using a transparent reinforcing material, resulting in a reinforcing layer composed of a plurality of reinforcing portions. Wherein the electrode connection region may include at least one of: the first electrode and the area where the first electrode connecting part is connected, and the second electrode and the area where the second electrode connecting part is connected. Wherein the reinforcement part covers at least the first interconnection line and/or an interconnection line for connecting the second electrode with the second electrode connection part.
In this implementation, a solution of the transparent reinforcing material may be drop-coated in a drop-coating manner onto the electrode connection region where the reinforcement is to be created to form the reinforcement.
In step S15, the plurality of battery cells, the plurality of first electrode connection portions, the plurality of second electrode connection portions, the plurality of first interconnection lines, and the plurality of second interconnection lines are encapsulated by a transparent encapsulating material, so as to obtain a flexible and stretchable solar cell.
In this embodiment, the encapsulation process may be implemented by using a mold casting, a spin coating, a blade coating, and the like, and a person skilled in the art may set the encapsulation mode according to the material characteristics of the transparent encapsulation material, which is not limited in this disclosure.
In one possible implementation, step S11 may include: the method comprises the steps of depositing a conductive film on a hard substrate, processing the conductive film, and forming a plurality of first electrode connecting portions, a plurality of second interconnecting lines, a first output end and a second output end, wherein the first output end is connected to the first electrode connecting portions through the second interconnecting lines, and the second output end is connected to the second electrode connecting portions through the corresponding point second interconnecting lines. Wherein the first output terminal and the second output terminal are used for outputting the electric energy.
In the implementation mode, the required first output end and the second output end are simultaneously prepared while the plurality of first electrode connecting parts, the plurality of second electrode connecting parts and the plurality of second interconnecting wires are prepared, so that the battery manufacturing process is simplified, and the battery manufacturing speed is increased.
According to the manufacturing method of the flexible extensible solar cell, the process of manufacturing the cell is simple, the manufactured cell is good in flexibility and extensibility, when the cell is stressed to be bent, stretched, compressed and the like to be greatly deformed, the cell can still continuously and stably work to generate electric energy, the energy conversion efficiency is high, the cell can be used as a power source of wearable equipment, and the application range is wide.
It should be noted that, although the flexible malleable solar cell and the method of manufacturing the same are described above by taking the above embodiments as examples, those skilled in the art will appreciate that the disclosure should not be limited thereto. In fact, the user can flexibly set each part and step according to personal preference and/or actual application scene, as long as the technical scheme of the disclosure is met.
Having described embodiments of the present disclosure, the foregoing description is intended to be exemplary, not exhaustive, and not limited to the disclosed embodiments. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. The terms used herein were chosen in order to best explain the principles of the embodiments, the practical application, or technical improvements to the techniques in the marketplace, or to enable others of ordinary skill in the art to understand the embodiments disclosed herein.
Claims (8)
1. A flexible malleable solar cell, characterized in that it comprises: a plurality of battery cells, a plurality of first electrode connections, a plurality of second electrode connections, a plurality of first interconnect lines, a plurality of second interconnect lines, an encapsulation layer, and a malleable substrate,
the plurality of first electrode connecting parts and the plurality of second electrode connecting parts are placed above the extensible substrate, the first electrode connecting parts and the second electrode connecting parts are arranged in an array mode, the first electrode connecting parts and the second electrode connecting parts in the same row or the same column are alternately placed, and intervals exist among the plurality of first electrode connecting parts, among the plurality of second electrode connecting parts, and among the first electrode connecting parts and the second electrode connecting parts;
the adjacent first electrode connecting parts and the second electrode connecting parts are connected together through corresponding second interconnecting wires;
each battery unit is positioned above the corresponding second electrode connecting part and used for converting the received light energy into electric energy;
each battery cell includes a first electrode and a second electrode, the second electrode of each battery cell is connected to a second electrode connection part located under the battery cell, and the first electrode is connected to an adjacent first electrode connection part through a corresponding first interconnection line;
the encapsulation layer is a transparent material for encapsulating the plurality of battery cells, the plurality of first electrode connections, the plurality of second electrode connections, the plurality of first interconnect lines, the plurality of second interconnect lines onto the malleable substrate,
wherein the battery further comprises a first insulating layer and a second insulating layer:
the first insulating layer covers the plurality of first electrode connection parts, the plurality of second electrode connection parts and the plurality of second interconnection lines;
the second insulating layer located under the plurality of first electrode connection parts, the plurality of second electrode connection parts, and the plurality of second interconnection lines,
wherein the second interconnect line has a shape of malleable shape, a first portion of the first insulating layer overlying the second interconnect line has a shape that is the same as the shape of the second interconnect line that the first portion overlies, and a second portion of the second insulating layer underlying the second interconnect line has a shape that is the same as the shape of the second interconnect line overlying the second portion.
2. The battery of claim 1, wherein the first electrode and the second electrode are coplanar electrodes or coplanar electrodes,
when the first electrode and the second electrode are coplanar electrodes, the first electrode and the second electrode are both arranged on one surface of the battery unit away from the second electrode connecting part, the second electrode is connected with the second electrode connecting part through an interconnecting wire,
when the first electrode and the second electrode are different-surface electrodes, the first electrode is arranged on one surface of the battery unit far away from the second electrode connecting part, the second electrode is arranged on one surface of the battery unit close to the second electrode connecting part, and the second electrode is in contact connection with the second electrode connecting part.
3. The battery according to claim 1 or 2, further comprising a reinforcing layer,
the reinforcing layer includes a plurality of reinforcing parts, each reinforcing part is disposed at an electrode connection region corresponding to each battery cell, the electrode connection region including at least one of: the area of the first electrode and the first electrode connecting part connected with the first electrode, the area of the second electrode and the second electrode connecting part connected with the second electrode,
the reinforcing part at least covers the first interconnection line and/or the interconnection line for connecting the second electrode and the second electrode connecting part, and the reinforcing part is made of a transparent material.
4. The battery of claim 1, further comprising a first output terminal and a second output terminal, the first output terminal being connected to a first electrode connection portion by a corresponding second interconnect line, the second output terminal being connected to a second electrode connection portion by a corresponding second interconnect line,
the first output end and the second output end are used for outputting the electric energy.
5. The battery according to claim 1, wherein the battery cells in the plurality of battery cells are connected in series and/or parallel,
wherein the connection between the first electrode connection part and the second electrode connection part corresponds to the connection manner between the battery cells.
6. A method of manufacturing a flexible malleable solar cell, characterised in that it is used to manufacture a flexible malleable solar cell, according to any of the previous claims from 1 to 5, the method comprising:
depositing a conductive film on a hard substrate, and processing the conductive film to form a plurality of first electrode connecting parts, a plurality of second electrode connecting parts and a plurality of second interconnecting lines, wherein the first electrode connecting parts and the second electrode connecting parts are arranged in an array manner, and the first electrode connecting parts and the second electrode connecting parts in the same row or the same column are alternately arranged, and intervals exist among the plurality of first electrode connecting parts, among the plurality of second electrode connecting parts, and among the first electrode connecting parts and the second electrode connecting parts;
transferring the prepared plurality of first electrode connections, the plurality of second electrode connections and the plurality of second interconnect lines onto a pre-prepared malleable substrate;
respectively placing a plurality of battery units on the corresponding second electrode connecting parts, and realizing the connection between the second electrode of each battery unit and the lower second electrode connecting part;
enabling connection between the first electrode of each battery cell and the adjacent first electrode connection part using a plurality of first interconnection lines;
packaging the plurality of battery units, the plurality of first electrode connecting parts, the plurality of second electrode connecting parts, the plurality of first interconnecting lines and the plurality of second interconnecting lines by using a transparent packaging material to obtain a flexible and extensible solar battery,
wherein the method further comprises:
depositing a conductive film on a hard substrate and processing the conductive film to form a plurality of first electrode connection parts, a plurality of second electrode connection parts and a plurality of second interconnection lines, comprising:
generating a sacrificial layer on the hard substrate, and spin-coating an insulating material on the sacrificial layer to form a second insulating layer to be processed;
depositing a conductive film on the second insulating layer to be processed, and processing the conductive film to form a plurality of first electrode connecting parts, a plurality of second electrode connecting parts and a plurality of second interconnecting wires;
spin-coating an insulating material on the plurality of first electrode connecting parts, the plurality of second interconnecting lines and the exposed second insulating layer to be processed to form a first insulating layer to be processed;
processing the first insulating layer to be processed and the second insulating layer to be processed to obtain a first insulating layer and a second insulating layer,
wherein the second interconnect line has a shape of malleable shape, a first portion of the first insulating layer overlying the second interconnect line has a shape that is the same as the shape of the second interconnect line that the first portion overlies, and a second portion of the second insulating layer underlying the second interconnect line has a shape that is the same as the shape of the second interconnect line overlying the second portion.
7. The method of claim 6, further comprising:
generating a reinforcing part at an electrode connection region corresponding to each battery cell using a transparent reinforcing material before packaging to obtain a reinforcing layer composed of a plurality of reinforcing parts,
wherein the electrode connection region comprises at least one of: the area of the first electrode and the first electrode connecting part connected with the first electrode, the area of the second electrode and the second electrode connecting part connected with the second electrode,
wherein the reinforcement part covers at least the first interconnection line and/or an interconnection line for connecting the second electrode with the second electrode connection part.
8. The method of claim 6, wherein depositing a conductive film on a rigid substrate and processing the conductive film to form a plurality of first electrode connections, a plurality of second electrode connections, and a plurality of second interconnect lines comprises:
depositing a conductive film on a rigid substrate, and processing the conductive film to form a plurality of first electrode connection parts, a plurality of second interconnection lines, first output terminals and second output terminals, the first output terminals being connected to the first electrode connection parts through the corresponding second interconnection lines, the second output terminals being connected to the second electrode connection parts through the corresponding second interconnection lines,
wherein the first output terminal and the second output terminal are used for outputting the electric energy.
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