Process Engineering of Semitransparent DSSC Modules and Panel Incorporating an Organic Sensitizer

Among the technologies adopted in the building-integrated photovoltaics sector, dye-sensitized solar cells appear very attractive because of unique features like tunable color and good transparency. However, the prospect of their low-cost fabrication is realistic only if reliable and scalable processes under real manufacturing conditions (i.e., pilot line and/or plant factory) are designed, developed, and optimized for large-area, efficient, and stable devices. Herein, a highly reproducible process is shown based on the deposition of different inks by screen-printing technique to realize twenty modules (400 cm2) and one panel (0.2 m2) incorporating an organic sensitizer. Module design considers the resistive losses caused by electron transport, the durability of the device and its aspect ratio (>70%). The module champion efficiency is 5.1% with 35.7% transparency (average visible transmittance), and its stability is determined to be >1000 h according to two International Summit on Organic Photovoltaic Stability (ISOS) protocols (D-2 and L-1). The modules show no structural failures, electrolyte leakage, or other signs of degradation. The consistency of the gap between photo- and counter-electrodes before and after stress is demonstrated. An industrial lamination process to realize a panel with an outdoor efficiency of 2.7% at 60 °C tilt angle is adopted.