Reproducible manufacturing of dye‐sensitized solar cells on a semi‐automated baseline

Abstract

A fully operational baseline consisting of dedicated equipment to process nanocrystalline dye‐sensitized solar cell devices has been installed at ECN. This baseline focuses on the production of glass/glass devices with dimensions up to 10×10 cm². Present power conversion efficiencies of 6% obtained for cell areas of 2ċ5 cm² are successfully translated to 100 cm² devices with an active area of 68 cm² by application of identical cell components. The power conversion efficiency with respect to total area was 4%. Processing of a large number of devices in the baseline shows good results in terms of process reliability and yield. The overall yield for a series of 27 devices (10×10 cm²) was 96%, while 84% (22 of the remaining 26 devices) generated a cell efficiency within 7% deviation from the average value (4ċ3%). The reproducibility of the titanium dioxide (TiO₂) colloid synthesis has been investigated. The deviation from the average efficiency (4ċ9%) of three batches of colloid was at most 3ċ2%. These results prove that complete device manufacturing of nc‐DSC by a baseline process, starting with colloid synthesis is reproducible for surfaces up to 10×10 cm². Copyright © 2003 John Wiley & Sons, Ltd.