Dye sensitised solar cells from laboratory scale to pre-pilot stage

At ECN Solar Energy, the dye sensitised solar cell (nc-DSC) is developed from laboratory scale to the pre-pilot module stage. The process line with mechanised equipment for 10/spl times/10 and 7.5/spl times/10 cm/sup 2/ devices is presented. Power conversion efficiencies of 6% obtained for cell-areas of 2.5 cm/sup 2/ are successfully translated to 100 cm/sup 2/ devices (active-area 68 cm/sup 2/) by application of identical cell components. Reproducible efficiencies of 6.0 /spl plusmn/ 0.3% are achieved at high yields of over 85%. These results prove that complete device manufacturing of nc-DSC using a baseline process, starting with colloid synthesis is reproducible for surfaces up to 10/spl times/10 cm/sup 2/. Four-cell 30/spl times/30 cm/sup 2/ modules are constructed to verify the feasibility of translating critical process steps carried out on 10/spl times/10 cm/sup 2/ to 30/spl times/30 cm/sup 2/. Cost calculations based on the present processing schemes (semi-automated) indicate a cost level of 2.5 Euro/Wp at 1 MWp/year capacity, of which labour amounts to 40%.