Researchers at the Fraunhofer Institute for Polymer Applications in Germany are pioneering a groundbreaking development: organic solar cell modules embedded in ultra-thin glass. This innovative approach leverages glass not only as an excellent sealing material but also as a durable substrate that can withstand high processing temperatures, up to 400°C. Organic photovoltaic (OPV) modules are emerging as a promising alternative to traditional silicon-based solar cells due to their flexibility, lightweight design, and potential for cost-effective manufacturing.
One of the key advantages of OPVs is that they can be produced at atmospheric pressure, making them easier to handle compared to inorganic solar cells. Moreover, they can be manufactured using printing techniques, which significantly speeds up the production process and reduces costs. The success of this method relies heavily on the use of a flexible substrate, and that’s where Corning comes in. The special glass provided by Corning is unlike regular glass—it can be made as thin as 100 microns, roughly the thickness of a sheet of paper, allowing it to be used as a robust yet flexible carrier.
The collaboration between scientists and Corning has already led to the creation of the first functional organic solar cell module using a "chip-to-film" process. Building on this, the team has now tested a "roll-to-roll" process, similar to how newspapers are printed. In this method, the glass substrate is wound onto a roll and passed through multiple stages where the photoactive layer and electrodes are applied. This technique allows for continuous and scalable production, and the team successfully created a uniform layer on a smaller substrate for the first time.
While the technology is still in development, researchers are working on refining the process to make it suitable for large-scale industrial production. In the future, this innovation could lead to high-strength, high-performance organic solar cells tailored for various applications—ranging from small-scale uses like powering mobile devices to large-scale solar farms. This advancement marks a significant step toward more versatile and sustainable energy solutions.
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