Performance and stability of dye solar cells on stainless steel

This study is on nanostructured dye solar cells which are easy to manufacture and use low cost materials. Dye solar cells have conventionally been deposited on conductive glass sheets. To reduce the costs and enable roll-to-roll mass production, the glass substrates should be replaced with flexible metal and plastic substrates. The change of the substrates has a profound effect on the cell, e.g. on electrochemical properties, optics, temperature treatments, and lifetime which all change when using alternative substrates. In this work, the focus is on using stainless steel and ITO-PET substrates in dye solar cells. The electrochemical characteristics of the substrates were analyzed and the need for additional coatings to improve the performance or the stability was evaluated. The optimization of the other cell components in different metal-plastic cell configurations was also examined. An important part of the work was to decouple the effects of the different cell components on the cell performance. For this purpose, a method to study individual electrode performance based on electrochemical impedance measurements of a complete cell is presented. Issues related to the up-scaling of the cell, namely current collection and spatial performance distribution, are also covered in this work. A novel, segmented cells configuration is presented to study the spatial performance distribution. It was discovered that there are large variations in the cell performance leading to significant efficiency losses. The spatial distribution was linked with the usual electrolyte filling technique which resulted in an uneven distribution of a common electrolyte component, 4-tert-butylpyridine. Finally, the lifetime of the stainless steel based cells was examined. Interestingly, the cells with stainless steel photoelectrode substrates aged much faster than those with stainless steel counter electrode substrates. To examine the aging mechanisms, a segmented cell design was also developed specially for the degradation studies. With the segmented cells, it could be confirmed that the degradation of the stainless steel photoelectrode cells was not due to changes in the electrolyte. The aging of the stainless steel counter electrode cells was, on the contrary, linked with the corrosion of the stainless steel substrate by the electrolyte

Spatial distribution and decrease of dye solar cell performance induced by electrolyte filling

The spatial performance variation of dye solar cell with standard liquid electrolyte was examined by dividing the cell into segments. Surprisingly large and permanent performance differences were found in different parts of the cell leading to significant losses in the overall cell efficiency. The decrease of open circuit voltage along the electrolyte filling direction suggests that 4-tert-butylpyridine is adsorbed non-uniformly as the electrolyte passes through the dyed TiO2 layer during the filling process. The result indicates that non-uniform electrolyte adsorption may limit the up-scaling of dye solar cells, which calls for the examination of electrolyte filling techniques and electrolyte compositions less prone to this effect.Peer reviewe

Segmented Cell Design for Improved Factoring of Aging Effects in Dye Solar Cells

A new segmented cell design was applied to study the aging of dye solar cell with stainless steel (StS) photoelectrode substrate, in particular the role of electrolyte in the degradation. Photovoltaic characterization indicated that StS photoelectrode cells are subjected to rapid (within hours or days) performance degradation that did not occur in the StS counter electrode cells. Other complementary techniques, open circuit voltage decay (OCVD) and electrochemical impedance spectroscopy (EIS), showed changes in the recombination at the photoelectrode/electrolyte interface. With the segmented cell method, we confirmed that the electrolyte was not contaminated by the StS nor was it subject to other significant changes related to the rapid degradation.Peer reviewe

Metallic and plastic dye solar cells

Dye solar cells (DSCs) are quite a new technology in photovoltaics. The traditional DSCs are prepared on conductively coated glass substrates in high temperature using a batch process. Manufacturing the cells on low-cost metal and plastic substrates would enable significant cost reductions as well as roll-to-roll mass production. There is a selection of metals and possible conducting coatings for plastics with varying electrical, optical, and chemical properties and price. The substrate has a dominant impact on the methods and materials that can be applied to make the cell and consequently on the resulting performance of the device. Furthermore, the substrates influence significantly the stability of the device. The main issue with plastics is their permeability whereas with metals, chemical stability in the electrolyte is themain concern. The leakage of electrolyte and the impact of water intake through the plastics can be affected by the material choices in particular with the electrolyte and dye composition. In the case of the metallic electrodes, the chemical stability can be improved by choosing a corrosion-resistant metal, applying a blocking layer or changing to a less aggressive electrolyte. One major focus of the current research of the flexible DSCs is increasing the efficiency by improved low-temperature preparation methods and materials especially for the photoelectrode. Another significant challenge is the development of noncorrosive electrolyte and dye combinations that work well even in the presence of significant amounts of water.Peer reviewe

Two-Dimensional Time-Dependent Numerical Modeling of Edge Effects in Dye Solar Cells

A two-dimensional transient model of dye solar cells (DSC) describing the electrochemical reactions in the cell has been prepared. The model includes the relevant components of DSCs: the photoelectrode, the electrolyte, and the counter electrode. The solved variables are potential and the concentrations of the different ion species, which can be used to determine, e.g., the current−voltage characteristics of the cell. The largest benefit of this model is its 2D features which enable the study of lateral inhomogeneity. Using the model, a new phenomenon was described: lateral current density distribution caused by a small difference in the size between photoelectrode and counter electrode, typical of laboratory test cells, causes tri-iodide to move from the edge region to the active area of the cell. This process takes a relatively long time (8 min) and can be important for performance characterization and design of DSCs.Peer reviewe

Stabilization of metal counter electrodes for dye solar cells

The purpose of this study was to identify stable metal based counter electrodes (CE) for dye solar cells (DSC). Previous studies have shown that stainless steel (StS 304) suffers from corrosion when used as a counter electrode. Therefore metals which have inherently higher corrosion resistance, such as stainless steel types 321, 316 and 316L, Inconel 600 and titanium, were investigated here. When using thermal platinization for the preparation of the catalyst layer on CE, only the titanium foil based metal based DSC remained consistently stable in the 1000 h light soaking test. The counter electrodes were also prepared with sputtering ∼20 nm thick layer of Pt which provides a highly uniform layer on the CE which acts also as a protective coating on the metal. With sputtered Pt, DSC on all studied metals expect for Inconel remained at 80–95% of the initial efficiency after light soaking test for 1000 h.Peer reviewe

Dye Solar Cells on ITO-PET Substrate with TiO[sub 2] Recombination Blocking Layers

Atomic-layer-deposited TiO2 recombination blocking layers were prepared on indium tin oxide–poly(ethylene terephthalate) (ITO–PET) photoelectrode substrates for dye solar cells and were examined using several electrochemical methods. The blocking layers increased the open-circuit voltage at low light intensities. At high light intensities, a decrease in the fill factor (FF) due to the additional resistance of the current transport through the layer was more significant than the positive effect by the reduced recombination. The decrease in the FF was reduced by a thermal treatment that made the blocking layer more conductive due to a structural change from an amorphous to a crystalline form. Therefore, thinner blocking layers of this type are required for plastic cells prepared at low temperature than for conventional glass dye solar cells made with temperature processing.Peer reviewe

The effect of electrolyte filling method on the performance of dye-sensitized solar cells

The effect of electrolyte filling method on the performance of the dye-sensitized solar cells is investigated with the segmented cell method, a recent technique which is very simple but effective as it can be used to examine all the photovoltaic characteristics. The electrolyte filling techniques compared were single injection, which is typically used in small laboratory cells, and pumping the electrolyte through the cell several times, which is often used for larger cells and modules. Significant photovoltage and photocurrent variations occur with the repeated pumping of the electrolyte in the cell preparation. Transient and charge extraction measurements confirmed that the differences in open circuit voltage were due to the shifts of the TiO2 conduction band and time correlated single photon counting confirmed that the reduction of short circuit current was largely due to reduced electron injection correlated with the increasing conduction band edge in the studied cases. This was interpreted as an effect of molecular filtering by the TiO2 causing an accumulation of electrolyte additives (4-tert-butylpyridine and benzimidazole) near the electrolyte filling hole, the concentration of which increased with repeated pumping of the electrolyte. Interestingly, spatial variations were seen not only in the relative TiO2 conduction band energy but also in the density of trap states. In this contribution it is demonstrated how the changes in the conduction band can be separated from the changes in the density of trap states which is an essential for the correct interpretation of the data.Peer reviewe

A carbon gel catalyst layer for the roll-to-roll production of dye solar cells

Carbon gel catalyst layers were used in dye solar cells. These layers were prepared on flexible plastic substrates at low temperatures (130 °C). The carbon gel, demonstrated excellent flexibility which is an important feature for roll-to-roll production and special applications of dye solar cells. The use of these low cost and highly flexible catalyst layers resulted in good photovoltaic performance; only 10% lower than dye solar cells with rigid glass-based counter electrodes prepared with thermal platinization at ∼400 °C temperature.Peer reviewe

Nanocellulose aerogel membranes for optimal electrolyte filling in dye solar cells

A new method for depositing electrolyte in dye solar cells (DSCs) is introduced: a nanocellulose hydrogel membrane is screen printed on the counter electrode and further freeze-dried to form a highly porous nanocellulose aerogel, which acts as an absorbing sponge for the liquid electrolyte. When the nanoporous dye-sensitized TiO2 photoelectrode film is pressed against the wetted aerogel, it becomes filled with the electrolyte. The electrolyte flows inside the TiO2 film only about ten micrometers (i.e. the TiO2 film thickness) whereas in the conventional filling method, where the electrolyte is pumped through the cell, it flows about 1000-times longer distance, which is known to cause uneven distribution of the electrolyte components due to a molecular filtering effect. Furthermore, with the new method there is no need for electrolyte filling holes which simplifies significantly the sealing of the cells and eliminates one common pathway for leakage. Photovoltaic analysis showed that addition of the nanocellulose aerogel membrane did not have a statistically significant effect on cell efficiency, diffusion in the electrolyte or charge transfer at the counter electrode. There was, however, a clear difference in the short circuit current density and open circuit voltage between the cells filled with the aerogel method and in the reference cells filled with the conventional method, which appeared to be caused by the differences in the electrolyte filling instead of the nanocellulose itself. Moreover, accelerated aging tests at 1 Sun 40 °C for 1000 h showed that the nanocellulose cells were as stable as the conventional DSCs. The nanocellulose aerogel membranes thus appear inert with respect to both performance and stability of the cells, which is an important criterion for any electrolyte solidifying filler material.Peer reviewe