TWI784672B - Packaging structure for flexible organic solar cell module and packaging method thereof - Google Patents

Abstract

A packaging structure for flexible organic solar cell module and packaging method thereof are provided. The package structure includes a first barrier layer, a first adhesive layer, a second barrier layer, a second adhesive layer, and a solar cell module. The first barrier layer, the first adhesive layer, the second barrier layer, the second adhesive layer are combined with each other in a thermal compression bonding method. The packaging method includes providing a first barrier layer and a second barrier layer respectively having a first surface and second surface opposite to the first surface; forming a first adhesive layer on the second surface of the first barrier layer; forming a second adhesive layer on the first surface of the second barrier layer; setting the solar cell module between the first adhesive layer and the second adhesive layer; combining the first barrier layer, the first adhesive layer, the solar cell module, the second adhesive layer and the second barrier layer with each other in a thermal compression bonding method.

Description

Encapsulation structure and encapsulation method for flexible organic solar cell module

The invention relates to an organic solar battery, in particular to a packaging structure and packaging method for a flexible organic solar battery module.

Organic solar cells have high photoelectric conversion efficiency in low-light environments. Therefore, in recent years, they have been gradually discussed as power sources for low-power electronic devices. The emergence of the Internet of Things has not only changed the way we work and live, And it has created an application stage for Organic Photovoltaic (OPV) to show its full potential. However, lifetime will be a key factor affecting solar cell cutting into the above application.

OPV packaging technology is mostly developed on hard glass substrates, and soft substrates are rarely used as research and development targets. Conventional technologies often use high-cost manufacturing methods on barrier films (for example, Sputtering, vapor deposition, plasma-assisted chemical vapor deposition) are used to cover the gas barrier film layer to increase the gas barrier rate, but the gas barrier film layer has doubts about affecting light penetration and bendability. In addition, the organic solvent in the encapsulation product may also react with the film layer in the OPV, thereby destroying the efficiency and life of the organic solar cell module.

In addition, in the prior art, a multi-layer stacked packaging method is used to improve the gas barrier capability of the organic solar cell module. However, the packaging method of multi-layer stacking will inevitably lead to an increase in cost, and will lead to problems of reducing light penetration and bendability.

Therefore, how to provide a "packaging structure and packaging method for flexible organic solar cell modules" has become a problem to be solved in the industry.

An embodiment of the present invention provides a packaging structure for a flexible organic solar cell module, comprising a first barrier layer having a first surface and a second surface opposite to the first surface; a first adhesive layer formed on the first barrier layer The second surface of the second barrier layer; the second barrier layer has the first surface and the second surface opposite to the first surface; the second adhesive layer is formed on the first surface of the second barrier layer; the solar cell module is arranged on the first surface Between the adhesive layer and the second adhesive layer; wherein the first barrier layer, the first adhesive layer, the solar cell module, the second adhesive layer and the second barrier layer are combined with each other in a heat-pressing manner.

In some embodiments, at least one through hole is formed at one end of the first barrier layer, the first adhesive layer, the solar cell module, the second adhesive layer, and the second barrier layer.

In some embodiments, an electrode is embedded in at least one through hole, and one end of the electrode protrudes from the first surface of the first barrier layer to form an electrode contact point.

In some embodiments, a filling glue is further included to cover the electrode contact points.

In some embodiments, the first adhesive layer and the second adhesive layer cover the solar cell module.

In some embodiments, the first adhesive layer and the second adhesive layer are pressure-sensitive adhesives.

In another embodiment, the present invention provides a packaging method for a flexible organic solar cell module, which includes the following steps: providing a first barrier layer and a first barrier layer respectively having a first surface and a second surface opposite to the first surface. The second barrier layer; forming the first adhesive layer on the second surface of the first barrier layer; forming the second adhesive layer on the first surface of the second barrier layer; disposing the solar cell module on the first adhesive layer and the second adhesive layer between; and combining the first barrier layer, the first adhesive layer, the solar cell module, the second adhesive layer and the second barrier layer with each other in a thermocompression bonding manner.

In some embodiments, after the step of arranging the solar cell module between the first adhesive layer and the second adhesive layer, the following steps are further included: on the first barrier layer, the first adhesive layer, the solar cell module, At least one through hole is formed between the second adhesive layer and one end of the second barrier layer; an electrode is embedded in the at least one through hole, and one end of the electrode protrudes from the first surface of the first barrier layer to form an electrode contact point; and Apply a filling gel to the electrode contact point.

In some embodiments, after the step of disposing a solar cell module between the first adhesive layer and the second adhesive layer, it further includes vacuum baking the first barrier layer, the first adhesive layer, the solar cell module, The step of the second adhesive layer and the second barrier layer.

In order to make the present invention more comprehensible, the following specific embodiments are described in detail in conjunction with the accompanying drawings.

The specific implementation manners of the present invention will be further described below in conjunction with the accompanying drawings and examples. The following examples are only used to illustrate the technical solutions of the present invention more clearly, but not to limit the protection scope of the present invention.

For the sake of clarity and convenience of drawing description, the size and proportion of each component in the drawing may be presented enlarged or reduced. In the following description and/or claims, when it is mentioned that an element is "connected" or "coupled" to another element, it may be directly connected or coupled to the other element or there may be an intervening element; When "directly connected" or "directly coupled" to another element, there are no intervening elements, and other words used to describe the relationship between elements or layers should be construed in the same way; "first", "second", Ordinal numbers such as "third" have no sequential relationship with each other, and are only used to mark and distinguish two different components with the same name. To facilitate understanding, the same components in the following embodiments are described with the same symbols.

Please refer to FIG. 1A, which is a schematic structural diagram of a solar cell module according to an embodiment of the present invention. As shown in FIG. 1A , the solar cell module 10 includes: a flexible substrate 11 , a transparent conductive layer 12 , an electron transport layer 13 , an active layer 14 , and a hole transport layer/top electrode 15 . The solar cell module 10 has the property of being bendable.

The flexible substrate 11 is located under the transparent conductive layer 12 . The transparent conductive layer 12 is located below the electron transport layer 13 . The electron transport layer 13 is located below the active layer 14 . The active layer 14 is located below the hole transport layer/top electrode 15 . Next, the manufacturing flow of the solar cell module 10 will be described.

Substrate surface treatment: use a soft substrate 11, and plan to separate single cell areas on it by laser lift-off process planning. Next, use isopropanol and acetone to wipe and remove the dirt and dust on the surface of the flexible substrate 11 . Then, a UV-ozone cleaning machine is used to remove surface pollutants, so as to improve the adhesion of the transparent conductive layer 12 and the electron transport layer 13 to the soft substrate 11 .

Electron transport layer and active layer coating: On the surface-treated flexible substrate 11, coat the electron transport layer 13 and the active layer 14 in sequence, and after coating each layer, dry it by heat treatment , to avoid mutual influence between layers.

Evaporating the hole transport layer and the upper electrode: the solar cell module 10 after the coating of the active layer 14 is completed, and the prefabricated mask (mask) is attached to define the position of each element in the solar cell module 10, and placed Vacuum the chamber of the vapor deposition machine, and wait until the pressure in the chamber reaches below the set value for vapor deposition, and change the plating rate by adjusting the current to meet the appropriate uniformity of the film layer. When the thickness reaches the requirement, the fabrication of the vapor-deposited hole transport layer/top electrode 15 is completed.

Please refer to FIG. 1B to FIG. 1G , which are schematic diagrams of the packaging structure of the solar cell module according to the embodiment of the present invention. As shown in FIG. 1B and FIG. 1C , a first barrier layer 20 and a second barrier layer 22 are provided. The first barrier layer 20 has a first surface 20a and a second surface 20b opposite to the first surface 20a. The second barrier layer 22 has a first surface 22a and a second surface 22b opposite to the first surface 22a.

The first adhesive layer 30 is formed on the second surface 20 b of the first barrier layer 20 . The second adhesive layer 32 is formed on the first surface 22 a of the second barrier layer 22 . The first adhesive layer 30 is formed on the second surface 20b of the first barrier layer 20 by transfer printing. The second adhesive layer 32 is formed on the first surface 22a of the second barrier layer 22 by transfer printing. In fact, the first adhesive layer 30 and the second adhesive layer 32 can be, for example, pressure sensitive adhesive (PSA).

It is worth noting that during the transfer process, attention should be paid to avoid air bubbles between the first adhesive layer 30 and the first barrier layer 20 . Because the air bubbles contain water vapor and oxygen, the solar cell module 10 will be deteriorated and its service life will be affected. Likewise, attention should be paid to avoid air bubbles between the second adhesive layer 32 and the second barrier layer 22 , because the air bubbles contain moisture and oxygen, which will cause deterioration of the solar cell module 10 and affect its lifespan.

In addition, the first adhesive layer 30 and the second adhesive layer 32 are solvent-free adhesives. Therefore, the first adhesive layer 30 and the second adhesive layer 32 will not react with the first barrier layer 20 and the second barrier layer 22 , so the efficiency and service life of the solar cell module 10 will not be affected. The first barrier layer 20, the first adhesive layer 30, the second adhesive layer 32, and the second barrier layer 22 have the characteristics of light transmission and flexibility, so there will be no problems of reducing light penetration and bendability. .

As shown in FIG. 1C and FIG. 1D , the solar cell module 10 is disposed between the first adhesive layer 30 and the second adhesive layer 32 . The first adhesive layer 30 is combined with the second adhesive layer 32 to form a third adhesive layer 34 . The first adhesive layer 30 , the second adhesive layer 32 and the third adhesive layer 34 are made of the same material. As shown in FIG. 1D, in some embodiments of the present invention, in order to improve the packaging quality, the first barrier layer 20, the third adhesive layer 34, the solar cell module 10 and the second barrier layer 22 can be vacuum baked, In order to reduce the residual water and oxygen content of the first barrier layer 20 , the third adhesive layer 34 and the second barrier layer 22 . The condition of vacuum baking can be 100°C~110°C, and the time is more than 7 hours~9 hours. Then, stop the vacuum baking and cool down to normal temperature naturally.

As shown in FIG. 1D , the first barrier layer 20 , the third adhesive layer 34 , the solar cell module 10 and the second barrier layer 22 are bonded to each other in a thermocompression bonding manner. As shown in FIG. 1E , a through hole 40 is formed at one end of the first barrier layer 20 , the third adhesive layer 34 , the solar cell module 10 and the second barrier layer 22 .

As shown in FIG. 1F , the electrode 54 is embedded in the through hole 40 , and one end of the electrode 54 protrudes from the first surface 20 a of the first barrier layer 20 to form the electrode contact point 50 . The other end of the electrode 54 protrudes from the second surface 22 b of the second barrier layer 22 to form an electrode contact point 52 . In fact, the electrode contact points 50 and the electrode contact points 52 can be, for example, button nails or other fasteners with conductive materials. As shown in FIG. 1G , the filling glue 60 is coated on the electrode contact point 50 and the electrode contact point 52 . Actually, the filling glue 60 can be, for example, an interface adhesive, a light-curable adhesive or an ultraviolet-curable glue.

It is worth noting that, since the electrode contact points 50 and the electrode contact points 52 are exposed to contact with the outside, it will lead to the possibility of water and oxygen intrusion, and further damage the solar cell module 10 . Therefore, the embodiment of the present invention covers the electrode contact point 50 and the electrode contact point 52 with the filling glue 60 to effectively block the intrusion of water and oxygen.

Please refer to FIG. 2A and FIG. 2B , which are flow charts of the packaging method of the embodiment of the present invention. As shown in FIG. 2A , first, step S200 , providing a first barrier layer 20 and a second barrier layer 22 respectively having a first surface and a second surface opposite to the first surface.

Step S210 , forming a first adhesive layer 30 on the second surface 20 b of the first barrier layer 20 . Step S220 , forming a second adhesive layer 32 on the first surface 22 a of the second barrier layer 22 . In addition, there is no sequence between step S210 and step 220 . In some embodiments, step S210 and step 220 may be performed simultaneously. In other words, step S210 and step S220 can be combined into one step.

Step S230 , disposing a solar cell module 10 between the first adhesive layer 30 and the second adhesive layer 32 . Step S240 , vacuum baking the first barrier layer 20 , the first adhesive layer 30 , the solar cell module 10 , the second adhesive layer 32 and the second barrier layer 22 . In some embodiments, step S240 may be omitted.

As shown in FIG. 2B , in step S250 , the first barrier layer 20 , the first adhesive layer 30 , the solar cell module 10 , the second adhesive layer 32 and the second barrier layer 22 are bonded together in a thermocompression bonding manner. In step S260 , at least one through hole 40 is formed on the first barrier layer 20 , the first adhesive layer 30 , the solar cell module 10 , the second adhesive layer 32 and one end of the second barrier layer 22 .

Step S270 , embedding an electrode 54 in at least one through hole 40 , and one end of the electrode 54 protrudes from the first surface 20 a of the first barrier layer 20 to form an electrode contact point 50 . Step S280 , coating a filling glue 60 on the electrode contact point 50 .

Please refer to FIG. 3 , which is a schematic diagram of the experimental results of the efficiency and time of the embodiment of the present invention and the conventional technology. As shown in Figure 3, the horizontal axis is time and the vertical axis is efficiency value. The conditions of the accelerated damp heat test are a temperature of 65 degrees Celsius and a humidity of 65%.

The first group of solar cell modules 100: no encapsulation structure (that is, only the solar cell modules 10). The second group of solar cell modules 110: no encapsulation structure (that is, only the solar cell modules 10). The third group of solar cell modules 120: there is an encapsulation structure (that is, including the first barrier layer 20, the first adhesive layer 30, the solar cell module 10, the second adhesive layer 32 and the second barrier layer 22), but no filling glue 60 covers the electrode contact point 50 and the electrode contact point 52 . The fourth group of solar cell modules 130 : has a packaging structure (same as the description of the third group of solar cell modules 120 ), and has filling glue 60 covering the electrode contact points 50 and electrode contact points 52 . The fifth group of solar cell modules 140 : has a packaging structure (same as the description of the third group of solar cell modules 120 ), and has filling glue 60 covering the electrode contact points 50 and electrode contact points 52 .

Generally speaking, it will be verified by accelerated testing, and then its real life will be estimated with an appropriate ratio. When the damp heat accelerated test was carried out to 200 hours, the efficiency values of the first group of solar cell modules 100 and the second group of solar cell modules 110 had dropped to 80% of the initial values, while the efficiency values of the third group of solar cell modules 120 The efficiency value is about 85% of the initial value, while the efficiency values of the fourth solar cell module group 130 and the fifth solar cell module group 140 are still above 90% of the initial value.

When the accelerated damp heat test is performed for 500 hours, the efficiencies of the first group of solar cell modules 100 and the second group of solar cell modules 200 have dropped below 60% of the initial values. The efficiency of the third group of solar cell modules 120 is about 75% of the initial value, while the efficiency values of the fourth group of solar cell modules 130 and the fifth group of solar cell modules 140 are still above 90% of the initial value. It can be seen from the foregoing that, after the accelerated humidity test has been performed for 500 hours, the fourth set of solar battery modules 130 and the fifth set of solar battery modules 140 still have a good service life.

When the accelerated humidity test lasted for 1000 hours, the efficiencies of the first group of solar cell modules 100 and the second group of solar cell modules 200 had dropped below 50% of the initial values. The efficiency of the third group of solar cell modules 120 is about 60% of the initial value, while the efficiency values of the fourth group of solar cell modules 130 and the fifth group of solar cell modules 140 are still above 90% of the initial value.

After 1500 hours of the accelerated damp heat test, the efficiency values of the fourth group of solar cell modules 130 and the fifth group of solar cell modules 140 are about 60% of the initial values. The filling glue 60 has been broken through, and the efficiency values of each group of solar cell modules are gradually consistent. If the encapsulation structure of the embodiment of the present invention is used, the lifespan of the solar cell module 10 can be more than doubled (for example, greatly increased from 3 years to more than 6 years).

To sum up, the packaging structure and packaging method for flexible organic solar cell modules of the present invention reduce the residual water and oxygen content of each film layer through vacuum baking, and cover the electrode contact points with filling glue to effectively block Possibility of water oxygen intrusion. Thereby, the service life of the flexible organic solar cell module can be greatly improved.

According to the embodiment of the present invention, the first adhesive layer and the second adhesive layer are solvent-free adhesives. Therefore, the first adhesive layer and the second adhesive layer will not react with the first barrier layer and the second barrier layer, so the efficiency and service life of the flexible organic solar cell module will not be affected.

According to the embodiment of the present invention, the first barrier layer, the first adhesive layer, the second adhesive layer and the second barrier layer have high light transmittance and bendable properties, so there will be no decrease in light transmittance and The problem of bendability.

Although the present invention has been disclosed above with the embodiments, it is not intended to limit the present invention. Anyone with ordinary knowledge in the technical field can make some changes and modifications without departing from the spirit and scope of the present invention. The scope of protection of the present invention should be defined by the scope of the appended patent application.

10:Solar battery module 11: Soft substrate 12: Transparent conductive layer 13: Electron transport layer 14:Active layer 15: Hole transport layer/top electrode 20: The first barrier layer 20a, 22a: first surface 20b, 22b: second surface 22: Second barrier layer 30: The first adhesive layer 32: Second adhesive layer 34: The third adhesive layer 40: through hole 50, 52: electrode contact point 54: electrode 60: filling glue 100: The first set of solar cell modules 110: The second group of solar cell modules 120: The third group of solar cell modules 130: The fourth group of solar cell modules 140: The fifth group of solar cell modules S200~S280: steps

FIG. 1A is a schematic structural diagram of a solar cell module according to an embodiment of the present invention. FIG. 1B to FIG. 1G are schematic diagrams of the package structure of the solar cell module according to the embodiment of the present invention. FIG. 2A and FIG. 2B are flow charts of a packaging method according to an embodiment of the present invention. Fig. 3 is a schematic diagram of the experimental results of the efficiency and time of the embodiment of the present invention and the conventional technology.

10:Solar battery module

11: Soft substrate

12: Transparent conductive layer

13: Electron transport layer

14:Active layer

15: Hole transport layer/top electrode

20: The first barrier layer

20a: first surface

22: Second barrier layer

22b: second surface

34: The third adhesive layer

50, 52: electrode contact points

54: electrode

60: filling glue

Claims (4)

A packaging structure for a flexible organic solar cell module, comprising: a first barrier layer having a first surface and a second surface opposite to the first surface; a first adhesive layer formed on the first The second surface of the barrier layer; a second barrier layer having a first surface and a second surface opposite to the first surface; a second adhesive layer formed on the first surface of the second barrier layer ; and a solar cell module, disposed between the first adhesive layer and the second adhesive layer; wherein the first barrier layer, the first adhesive layer, the solar cell module, the second adhesive layer and the The second barrier layer is vacuum-baked at 100°C to 110°C for 7 hours to 9 hours or more, and then combined with each other in a heat-compression method; wherein the first barrier layer, the first At least one through hole is formed at one end of the adhesive layer, the solar cell module, the second adhesive layer and the second barrier layer, and an electrode is embedded in the at least one through hole, and one end of the electrode protrudes from the first barrier layer On the first surface, the other end of the electrode protrudes from the second surface of the second barrier layer to respectively form an electrode contact point; and wherein a filling glue covers the electrode contact point. The encapsulation structure for a flexible organic solar cell module according to claim 1, wherein the first adhesive layer and the second adhesive layer cover the solar cell module. The encapsulation structure for a flexible organic solar cell module according to claim 1, wherein the first adhesive layer and the second adhesive layer are pressure-sensitive adhesives. A packaging method for a flexible organic solar cell module, comprising the steps of: providing a first barrier layer and a second barrier layer respectively having a first surface and a second surface opposite to the first surface; forming a first adhesive layer on the second surface of the first barrier layer; forming a second adhesive layer on the first surface of the second barrier layer; Set a solar cell module between the first adhesive layer and the second adhesive layer; vacuum bake the first barrier at 100°C to 110°C for 7 hours to 9 hours or more layer, the first adhesive layer, the solar cell module, the second adhesive layer, and the second barrier layer; the first barrier layer, the first adhesive layer, and the solar cell module are thermally bonded , the second adhesive layer and the second barrier layer are combined with each other; at least one end of the first barrier layer, the first adhesive layer, the solar cell module, the second adhesive layer and the second barrier layer is formed A through hole; an electrode is buried in the at least one through hole, and one end of the electrode protrudes from the first surface of the first barrier layer, and the other end of the electrode protrudes from the second surface of the second barrier layer to form an electrode contact point; and coating a filling glue on the electrode contact point.

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