Using inexpensive manufacturing methods to produce efficient solar cells

July 25th, 2011 by Science and Technology Facilities Council

A study, published in the Journal Advanced Energy Materials, paves the way for new solar cell manufacturing techniques and the promise of developments in renewable solar energy.  Efficient solar cell structures can be made using simple and inexpensive manufacturing methods – where flexible layers of material are deposited over large areas like cling-film.

Scientists from the University of Sheffield and the University of Cambridge used the ISIS Neutron Source and Diamond Light Source at STFC Rutherford Appleton Laboratory in Oxfordshire to carry out the research.

Plastic (polymer) solar cells are much cheaper to produce than conventional silicon solar cells and have the potential to be produced in large quantities. The study showed that when complex mixtures of molecules in solution are spread onto a surface, like varnishing a table-top, the different molecules separate to the top and bottom of the layer in a way that maximises the efficiency of the resulting solar cell.

Dr Andrew Parnell of the University of Sheffield said, “Our results give important insights into how ultra-cheap solar energy panels for domestic and industrial use can be manufactured on a large scale. Rather than using complex and expensive fabrication methods to create a specific semiconductor nanostructure, high volume printing could be used to produce nano-scale (60 nano-meters) films of solar cells that are over a thousand times thinner than the width of a human hair. These films could then be used to make cost-effective, light and easily transportable plastic solar cell devices such as solar panels.”

Dr Robert Dalgliesh prepares a sample on ISIS's offSPEC instrument at the STFC's Rutherford Appleton Laboratory (click image to expand - image courtesy of ISIS)

Dr. Robert Dalgliesh, one of the ISIS scientists involved in the work, said, “This work clearly illustrates the importance of the combined use of neutron and X-ray scattering sources such as ISIS and Diamond in solving modern challenges for society. Using neutron beams at ISIS and Diamond’s bright X-rays, we were able to probe the internal structure and properties of the solar cell materials non-destructively. By studying the layers in the materials which convert sunlight into electricity, we are learning how different processing steps change the overall efficiency and affect the overall polymer solar cell performance. ”

“Over the next fifty years society is going to need to supply the growing energy demands of the world’s population without using fossil fuels, and the only renewable energy source that can do this is the Sun”, said Professor Richard Jones of the University of Sheffield. “ In a couple of hours enough energy from sunlight falls on the Earth to satisfy the energy needs of the Earth for a whole year, but we need to be able to harness this on a much bigger scale than we can do now. Cheap and efficient polymer solar cells that can cover huge areas could help move us into a new age of renewable energy.”


The research, “The Nanoscale Morphology of a PCDTBT:PCBM Photovoltaic Blend, Advanced Energy Materials, was written by Paul A. Staniec, Andrew J. Parnell, Alan D. F. Dunbar, Hunan Yi, Andrew J. Pearson, Tao Wang, Paul E. Hopkinson, Christy Kinane, Robert M. Dalgliesh, Athene M. Donald, Anthony J. Ryan, Ahmed Iraqi, Richard A. L. Jones, and David G. Lidzey.

The research was funded with a grant from the Engineering and Physical Sciences Research Council (EPSRC). The collaboration has just been allocated a new grant to carry out further studies into the structure and function of polymer solar cell materials, as well as examining new materials and innovative processes for high volume manufacture and future commercialisation.

A conference about ways to harness the power of the Sun to tackle society’s energy challenge will take place in September 2011.

To find out more about UK research into photovoltaic devices visit the UK Optimisation of Photovoltaic Devices website.


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