WO2011002256A2

WO2011002256A2 - Apparatus for manufacturing dye-sensitized solar cell through continuous roll-to-roll process and manufacturing method thereof

Info

Publication number: WO2011002256A2
Application number: PCT/KR2010/004306
Authority: WO
Inventors: 신기현; 엄윤식; 강현규; 안진현
Original assignee: 건국대학교 산학협력단
Priority date: 2009-07-02
Filing date: 2010-07-02
Publication date: 2011-01-06
Also published as: WO2011002256A3; WO2011002256A9

Abstract

Disclosed is an apparatus for manufacturing a dye-sensitized solar cell through a continuous roll-to-roll process and a manufacturing method thereof. The present invention is a technique for manufacturing the dye-sensitized solar cell through a continuous process, which shortens the time required for each process by efficiently arranging existing processes for forming each of the functional layers, and also combines automation techniques by improving repetition of reproduction and the like. Thus, this design effectively shortens extended heat treatment periods and the chemical process time for forming and processing each of the functional layers, and produces dye-sensitized solar cells in a non-stop process by efficiently reducing the space required therefor.

Description

Dye-sensitized solar cell production equipment and production method through roll-to-roll continuous process

The present invention relates to a production apparatus and a method for producing a dye-sensitized solar cell through a roll-to-roll continuous process, and more specifically, to form each functional layer of a dye-sensitized solar cell (DSSC) using a flexible roll-to-roll continuous process. The present invention relates to a device and a method for producing a dye-sensitized solar cell (DSSC) using a continuous roll-to-roll continuous process that can effectively shorten the heat treatment and chemical process for a long time in processing.

Recently, due to the depletion of natural resources and environmental and stability issues for thermal and nuclear power generation, studies on solar and wind power, which are representative environmentally friendly green energy, are being actively conducted.

In particular, the photovoltaic power generation system that converts the light energy of the sun into electrical energy is attracting considerable attention as an alternative energy source of the future in terms of infinite and clean energy.

Due to these advantages, the solar power system is used in a wide variety of fields such as vehicles, toys, residential power generation and streetlights, as well as unmanned lighthouses, clock towers, and communication equipment that are remote from the grid.

The photovoltaic power generation system is composed of a solar cell module, a storage battery, and a power converter, although components thereof vary depending on the field of use of the system, the type of load, and location conditions.

The solar cell module converts light energy into electrical energy, the storage battery stores electrical energy generated from the solar cell module, and the power converter converts DC power generated through the solar cell module into AC power.

Among the solar cells, dye-sensitized solar cells (DSSC) have the following advantages.

Compared to the Si solar cell, the manufacturing cost is 1/5, which is more economical, unlike the existing solar cell, it can be bent and transparently manufactured, so that the application area is wide and the existing solar cell increases in temperature. The drive efficiency is drastically reduced, but the DSSC shows constant efficiency over a relatively wide temperature range.

In addition, the solar cell changes the altitude of the sun every hour, so the energy conversion efficiency is important according to the angle of incidence of light, but DSSC does not change the efficiency according to the angle of incidence of radiation, and the photoelectric efficiency is about 10% lower than conventional solar cells, Research and development is underway because of the advantages of manufacturing equipment and process technology.

However, although the DSSC can be made by hand in the laboratory, there is a problem that mass production is impossible because there is no mass production equipment for commercialization. (Please check whether the problem of the conventional technology is correct.)

In addition, conventionally, since the TiO 2 layer was dyed in such a manner that the TiO 2 layer was immersed in a dye, it was difficult to dye a large amount at a time.

The present invention has been made to solve the above problems, an object of the present invention to provide an apparatus and method for producing a dye-sensitized solar cell through a roll-to-roll continuous process that can continuously produce DSSC using a roll-to-roll continuous process. I would like to.

* In addition, to efficiently arrange existing processes to reduce the time required for each process, and to provide an apparatus and method for producing a dye-sensitized solar cell through a roll-to-roll continuous process that can be automated by improving repeatability. It is.

In addition, dye-sensitized dyes can be used to dye a large amount of TiO2 layers using a small amount of dye by not dyeing the TiO2 layer into the dye, but by spraying the dye while transferring the sintered TiO2 layer to a roller. It is to provide a method for producing a solar cell.

In order to achieve the above object, in the present invention, a printing unit for continuously printing a titanium dioxide (TiO2) layer on the material being transported by the spray method, and a sintering unit for sintering the titanium dioxide layer printed through the printing unit with hot air; Dye tank for dyeing by spraying the dye while transferring the material sintered titanium dioxide layer through the sintering unit to the multi-stage roller, water washing part for washing the material exiting the dye tank, and material washed in the water washing part A drying unit for drying the film with hot air, an electrolyte printing unit for forming an electrolyte on the dyed titanium dioxide layer, a sealing unit for forming a sealing material for sealing a portion where a printing pattern is not formed, and a protective film on the sealed material Dye-sensitized solar cell production apparatus through a roll-to-roll continuous process comprising a lamination unit for laminating It is a ball.

In the present invention, the sintering unit may be provided with an ultraviolet lamp, an infrared lamp, a hot air circulator in a single or mixed manner.

In the present invention, a dye circulation pump for recycling the dye accumulated in the lower end of the dye tank, a dye concentration adjusting device receiving the dye from the dye circulation pump, and a temperature controller for adjusting the temperature in the dye tank may be further installed. have.

In the present invention, the water washing unit may be made of a water tank for the first washing the material exiting the dye tank, and a pressure spray for second washing the material passed through the water tank.

Here, the water tank is characterized in that the remaining dye is installed by installing a vortex generator.

In the present invention, to prevent the leakage of the electrolyte to form a leak-proof layer around the electrolyte pattern, a blade for maintaining a uniform thickness of the electrolyte may be further included.

Method of producing a dye-sensitized solar cell of the present invention for achieving the above object is to form a titanium dioxide (TiO2) layer using a spray nozzle and a mask on the material being transported, the titanium dioxide (TiO2) Sintering the layers in a single or mixed manner by UV, IR, and hot air, spraying dye onto the transported material on which the titanium dioxide is printed, dyeing without immersion during transport, and washing the material exiting the dye tank. Drying the washed material with hot air, forming an electrolyte on the dyed titanium dioxide layer, forming a sealing material for sealing in the portion where the printing pattern is not formed, and attaching the sealing material. It may be made, including the step of laminating a protective film on the material.

In the present invention, controlling the reuse and concentration of the dye through the outlet of the bottom of the dye tank, by adjusting the level of the dye in the dye tank to change the range in contact with the material being transported, temperature control in the dye tank Through the step of changing the dyeing conditions may be further included.

In the present invention, after the step of forming the electrolyte may further comprise the step of installing the electrolyte leakage prevention layer and maintaining a uniform thickness using the blade.

In the present invention, the washing may be performed by first washing in a water tank and second washing through a pressurized spray.

In the present invention, the dyeing step may be dyed by spraying or dropping the dye on the top or side of the transporting material printed with titanium dioxide.

As described above, according to the production apparatus and method of the dye-sensitized solar cell through the roll-to-roll continuous process of the present invention, by efficiently arranging existing processes for forming each functional layer, the time required for each process may be shortened. In addition, there is an effect that can improve the reproduction repeatability.

In addition, it is designed to effectively shorten the heat treatment and chemical process for a long time in the formation and processing of each functional layer, and it is effective to produce dye-sensitized solar cell by non-stop process by efficiently utilizing the necessary space. .

Figure 1 shows the overall configuration of the present invention, a process diagram showing the final winding through the formation of the TiO 2 layer, sintering, dyeing, washing and drying of the TiO 2 layer, electrolytic printing, sealing material and the adhesion and sealing in order,

Figure 2 is a view for explaining the step of continuously printing on the material being transported by the TiO2 layer in the present invention,

3 is a view for explaining the step of sintering the TiO 2 layer printed material alone or in a mixed manner such as UV, IR and hot air;

Figure 4 is a sintered TiO2 layer is transported by a plurality of non-driven rollers or drive rolls are dyed to the dye is sprayed to the side from the top or the pipe between the rollers and the process of temperature control by the temperature controller Illustrated drawing,

FIG. 5 is a diagram illustrating a process in which a temperature controller for controlling a temperature in a dye tank is installed by circulating a dye accumulated at a lower end of a dye tank using a pump and then supplying it to a dye concentration adjusting device.

FIG. 6 is a view illustrating a process in which a material exiting a dye tank enters a water bath to be first washed, washed secondly through a pressurized spray, and passed through a dryer;

FIG. 7 illustrates a process of spraying a liquid sealing material through a spray method for sealing a portion where a printing pattern is not formed;

8 is a view showing a process of attaching a sealing material in the form of a tape for sealing on a portion where a print pattern is not formed;

9 illustrates a process of forming an electrolyte on a dyed TiO 2 layer through roll type printing (gravure, flexo, offset, etc.);

FIG. 10 is a view illustrating a process in which a laminated material of a pre-made conductive film and a protective film is mounted on a sealing material.

11 is a view for explaining a step of forming a leak prevention layer around the electrolyte pattern to prevent leakage of the electrolyte and to maintain a uniform thickness;

FIG. 12 is an overall process diagram in which the electrolyte printing is changed to the solid electrolyte lamination process according to another embodiment of the present invention.

The terms or words used in this specification and claims are not to be construed as limiting in their usual or dictionary meanings, and the inventors may properly define the concept of terms in order to best explain their invention in the best way possible. It should be interpreted as meaning and concept corresponding to the technical idea of the present invention.

Hereinafter, an embodiment of the present invention will be described in detail with reference to the drawings.

DSSC is largely composed of photoanode, dye (sensitizer), counter electrode (electrode) and electrolyte (electrolyte).

Titanium dioxide (Ti02) is used as the cathode material of DSSC because of its high efficiency and chemical stability.

1 is a view showing the overall configuration of the present invention, a process diagram showing the final winding through the TiO 2 layer formation, sintering, dyeing, washing and drying of the TiO 2 layer, electrolytic printing, adhesion of the sealing material and sealing in order.

As shown in the drawing, the production apparatus of the dye-sensitized solar cell of the present invention produces a dye-sensitized solar cell (DSSC) through a roll-to-roll continuous process, and a titanium dioxide (TiO 2) layer on the material being transferred by spraying. The printing unit 10 for continuously printing, the sintering unit 20 for sintering the titanium dioxide layer printed through the printing unit 10 with hot air, and the titanium dioxide layer sintered through the sintering unit 20 Dye tank 30 for dyeing by spraying the dye while transferring the material to the roller 31 of the multi-stage, water washing part 40 for washing the material exiting the dye tank 30, and the water washing part ( 40, a drying unit 50 for drying the material washed with hot air, an electrolyte printing unit 60 for forming an electrolyte on the dyed titanium dioxide layer, and a sealing material for sealing a portion where a printing pattern is not formed. Sealing portion 70 to be formed, and the It includes a lamination portion 80 for laminating a protective film on the material.

2 is a view for explaining the step of continuously printing a TiO2 layer on the material being transported in the spray method in the present invention, using a spray or pressure spray method to raise the mask 110 on the material 100 being transported It is a method of continuously printing a predetermined pattern through the nozzle (11).

3 is a view for explaining the step of sintering the TiO 2 layer printed material alone or in a mixed manner such as UV, IR, and hot air, wherein the sintered part 20 includes an ultraviolet lamp 21 and an infrared lamp 22. The hot air circulator is provided alone or in a mixed manner.

The number and arrangement positions of the ultraviolet lamp 21 and the infrared lamp 22 are adjusted in consideration of the transfer speed of the material 100, and the sintering time of the TiO 2 layer is shortened by controlling the temperature in the dryer through a hot air circulation method.

Figure 4 is a sintered TiO2 layer is transported by a plurality of non-driven rollers or drive rolls are dyed to the dye is sprayed to the side from the top or the pipe between the rollers and the process of temperature control by the temperature controller The illustrated figure.

As shown in FIG. 5, the dye tank 30 includes a dye circulation pump 32 for recycling dye accumulated at a lower end, a dye concentration adjusting device 33 receiving dye from the dye circulation pump 32, and In addition, a temperature controller 34 for controlling the temperature in the dye tank is installed. The dye used for the dyeing of the TiO 2 layer needs to maintain a constant concentration and thus needs a periodic dye supply. The dye circulation pump 32 and the dye concentration control device 33 play a role in this.

In the conventional dye-sensitized solar cell manufacturing process, it was difficult to dye a large amount at a time by immersing the TiO 2 layer in a dye, but in the present invention, as shown in FIG. Since the dye is sprayed and dyed, it provides a way to dye for a long time using a small amount of dye.

FIG. 6 is a view illustrating a process in which the material exiting the dye tank enters the water tank to perform the first washing, the second washing through the pressurized spray, and passes through the dryer, and includes a vortex forming apparatus in the water tank 41 during the first washing. 42) can effectively remove the residual dye on the surface of the material, at the time of the second washing with a clean cleaning solution through the pressurized spray (43) at the same time performs the last residual dye removal work.

FIG. 7 is a view illustrating a process of spraying a liquid sealing material through a spray method for sealing a portion where a printing pattern is not formed, and a sealing material is required for laminating and encapsulating a protective film and a material. There are various forms such as types.

FIG. 8 is a view illustrating a process of attaching a sealing material in a tape form to seal a portion where a printing pattern is not formed.

FIG. 9 is a view showing a process of forming an electrolyte on a dyed TiO 2 layer through roll type printing (gravure, flexo, offset, etc.), and using a commercial roll type printing apparatus, using a commercially available roll type printing apparatus to a required thickness. Print

When the sealing material is pressurized at high temperature, the adhesive becomes strong, and by using this property, it is heated by applying pressure to the sealing material while preventing the flow of electrolyte as much as possible by using a pressure roller with irregularities.

FIG. 11 is a view for explaining a step of forming a leakage preventing layer around the electrolyte pattern and maintaining a uniform thickness to prevent leakage of the electrolyte.

When the thickness of the electrolyte is thicker than the surrounding material, as shown in FIG. 11A, the electrolyte leaks during the lamination and encapsulation process.

Therefore, in order to prevent leakage of the electrolyte, a leakage preventing layer 61 is formed around the electrolyte pattern, and the blade 62 is shaved to maintain the thickness of the electrolyte to prevent leakage of the electrolyte.

11 (b) shows that the electrolyte leaks when the thickness is uneven because the blade is not cut.

The production method through the production apparatus of the dye-sensitized solar cell through the roll-to-roll continuous process of the present invention as follows.

First, the TiO2 layer is continuously printed on the material being transported by spraying, and when the printed material is sintered by a single or mixed method such as UV, IR, and hot air, the sintered TiO2 layer has a plurality of ratios. It is dyed by dyes which are conveyed by drive rollers or drive rolls and sprayed laterally in the tube between the top or rollers.

The dye accumulated in the lower end of the dye tank 30 is circulated using the pump 32 and then supplied to the dye concentration adjusting device 33. When the temperature controller 34 controls the temperature in the dye tank 30, the dye The material exiting the tank 30 enters the water tank 41 and undergoes the first washing, and is secondly washed through the pressurized spray 43 and then passes through the dryer 50.

Thereafter, an electrolyte is formed on the dyed TiO 2 layer through roll type printing (gravure, flexo, offset, etc.). In this case, in order to prevent leakage of the electrolyte, a leakage preventing layer is formed around the electrolyte pattern and the thickness is maintained uniformly using a blade.

Thereafter, a sealing material is formed to seal the portion where the print pattern is not formed.

In this case, as shown in FIG. 7, the liquid sealing material may be sprayed through a spray method, or as shown in FIG. 8, a sealing material in the form of a tape may be attached to seal the portion where the printing pattern is not formed. have.

Then, hot air is dried and pressurized for lamination of the material to which the sealing material is attached, and the conductive film and the protective film prepared.

As described above, the whole process of the present invention leads to the production through the final winding process through the formation of the TiO 2 layer, the sintering, dyeing, washing and drying of the TiO 2 layer, electrolytic printing, and the adhesion and sealing of the sealing material.

FIG. 12 is an overall process diagram in which the electrolyte printing is changed to the solid electrolyte lamination process according to another embodiment of the present invention. The solid electrolyte functions as an electrolyte layer in the dye-sensitized solar cell by embedding the electrolyte in a thin absorbent material.

In the present invention, it is possible to control the reuse and concentration of the dye through the dye circulation pump in the outlet of the bottom of the dye tank, it is possible to change the range of contact with the material being transported by adjusting the level of the dye in the dye tank.

An example of manufacturing the DSSC of the present invention is as follows. (Please confirm whether the contents are related to the present invention. If the contents may be deleted, it is preferable to delete them.)

First of all, two glass substrates of 150mm length and width are subjected to the isolation process by laser digging grooves for electrode placement and cell boundary.

Subsequently, it moves to a process of continuously drilling holes within a diameter of 3 mm to inject electrolyte liquid between two substrates later on the rear substrate edge. The sand master called small sand powder under strong pressure and made holes in the glass.

Next, they go through ultrasonic equipment that removes substrate impurities by ultrasonic vibration.

Subsequently, a titanium dioxide (TiO 2) layer was formed on the front glass substrate using screen printing equipment.

Electrodes are formed of silver along the trenches.

Titanium dioxide nanoparticles are responsible for transporting electrons to electrodes and for adsorbing dyes.

On the back substrate, electrodes are formed of platinum along the grooves. Subsequently, the two substrates enter the oven (annealing equipment) and undergo heat treatment to settle properly.

Now, it is a step of adsorbing a wine-colored dye on a glass substrate on which titanium dioxide is formed. The equipment consisted of three bins that could immerse 40 substrates in dye liquid at the same time. Soak for about 4 hours to allow the dye to adsorb. Then, the dye-coated substrate and the back substrate on which the platinum electrode is formed are subjected to a sealing process of attaching heat, pressure, and adhesive sealant, and then electrolyte is injected into the drilled hole, and the punched hole is covered with a cover glass to complete the DSSC.

The operating principle of the DSSC is that when sunlight (light) passes through the transparent electrode of the DSSC and irradiates a dye (dye) absorbed in the TiO2 nanocrystals, when the dye absorbs sunlight, the electron of the dye is in a ground state. It changes from the (Ground State) to the Excited State, that is, the photoexcitation state.

Electrons in the excited state jump to the conduction band of TiO2, and the injected electrons diffuse through the TiO2 film to reach the transparent electrode.

Electrons that reach the electrode are moved to the counter electrode through an external circuit.

On the other hand, dyes deprived of electrons in TiO2 are reduced by obtaining electrons from electrolytes (iodide ions) and iodine is oxidized to iodine, while iodine obtains electrons from the counter electrode. It is also reduced to iodide.

By repeating the redox process of this process, current can be obtained from sunlight.

While the invention has been described in detail with respect to the embodiments described, it will be apparent to those skilled in the art that various modifications and variations are possible within the spirit of the invention, and such modifications and variations belong to the appended claims.

The present invention relates to an apparatus and a method for producing a solar cell (DSSC), a long-term heat treatment and chemical process in the formation, processing, etc. of each functional layer of the dye-sensitized solar cell (DSSC) using a flexible roll-to-roll continuous process Since it can effectively reduce the number of dyes for dyeing can be used to reduce costs and protect the environment.

Claims

A printing unit which continuously prints a titanium dioxide (TiO 2) layer on the material being transported by the spray method;

A sintering unit for sintering the titanium dioxide layer printed through the printing unit with hot air;

A dye tank for dyeing by spraying a dye while transferring the sintered material of the titanium dioxide layer through the sintering part to a roller of multiple stages;

Washing unit for washing the material exiting the dye tank;

A drying unit drying the material washed in the water washing unit with hot air;

An electrolyte printing unit for forming an electrolyte on the dyed titanium dioxide layer;

A sealing portion for forming a sealing material to seal a portion where the print pattern is not formed; And

A lamination portion for laminating the protective film on the sealed material;

Dye-sensitized solar cell production apparatus through a roll-to-roll continuous process comprising a.
The method of claim 1,

The apparatus for producing a dye-sensitized solar cell through a roll-to-roll continuous process, characterized in that the sintering unit is provided with a UV lamp, an infrared lamp, a hot air circulator in a single or mixed manner.
The method of claim 1,

A dye circulation pump for recycling dye accumulated at the bottom of the dye tank,

A dye concentration adjusting device receiving dye from the dye circulation pump;

The apparatus for producing a dye-sensitized solar cell through a roll-to-roll continuous process, characterized in that a temperature controller for controlling the temperature in the dye tank is further installed.
The method of claim 1,

The water washing unit and the water tank for the first wash the material exiting the dye tank,

Apparatus for producing a dye-sensitized solar cell through a roll-to-roll continuous process, characterized in that the pressurized spray for washing the material passed through the water tank second.
The method of claim 4, wherein

The apparatus for producing a dye-sensitized solar cell through a roll-to-roll continuous process, characterized in that the vortex generator is installed in the tank to wash residual dye.
The method of claim 1,

The apparatus for producing a dye-sensitized solar cell through a roll-to-roll continuous process, further comprising a blade forming a leak-proof layer around the electrolyte pattern to prevent leakage of the electrolyte, and maintaining a uniform thickness of the electrolyte.
Raising a mask on the material being transferred and forming a titanium dioxide (TiO 2) layer using a spray nozzle;

Sintering the titanium dioxide (TiO 2) layer in a single or mixed manner of UV, IR and hot air;

Dyeing the dye without spraying it onto the material being transported on which titanium dioxide is printed;

Washing the material exiting the dye tank;

Drying the washed material with hot air;

Forming an electrolyte on the dyed titanium dioxide layer;

Forming a sealing material for sealing in a portion where the printing pattern is not formed; And

Stacking the protective film on the material to which the sealing material is attached;

Method for producing a dye-sensitized solar cell through a roll-to-roll continuous process comprising a.
The method of claim 7, wherein

Adjusting the reuse and concentration of the dye through an outlet at the bottom of the dye tank;

Adjusting the level of the dye in the dye tank to change the range of contact with the material being transported; And

Changing dyeing conditions through temperature control in the dye tank;

Method for producing a dye-sensitized solar cell through a roll-to-roll continuous process characterized in that it further comprises.
The method of claim 7, wherein

Method of producing a dye-sensitized solar cell through a roll-to-roll continuous process characterized in that it further comprises the step of installing an electrolyte leakage preventing layer after the step of forming an electrolyte and maintaining a uniform thickness using a blade.
The method of claim 7, wherein

The washing step, the first washing step in the water tank,

Method for producing a dye-sensitized solar cell through a roll-to-roll continuous process, characterized in that the secondary washing step through the pressurized spray.
The method of claim 10,

The method of producing a dye-sensitized solar cell through a roll-to-roll continuous process, characterized in that the vortex forming device is installed in the water tank to effectively remove the residual dye on the material surface.
The method of claim 7, wherein

The dyeing step is a method of producing a dye-sensitized solar cell through a roll-to-roll continuous process, characterized in that the dye is sprayed or dropped on the top or side of the transport material is printed titanium dioxide.