Assembly Considerations for Dye-Sensitized Solar Modules with Polymer Gel Electrolyte

Parallel, portable dye-sensitized solar cell modules with 5 X 5 cm(2) of area containing either a polymer gel electrolyte or a standard liquid electrolyte were assembled and characterized as a function of time. For modules sealed with the thermoplastic Surlyn, a rapid loss of performance was observed, due to an insufficient protection of the metallic current collectors (silver grids) of the module and, sometimes, also associated with electrolyte leakage. Similar results were obtained using a glass frit layer as the only material for protective overcoat of the silver grids. Thus, the combination of the Surlyn with a glass frit was investigated. The process based on the combination of two materials allowed achieving a more effective sealing, with enhanced process yield and sample reproducibility. The modules assembled by this method, filled with either a polymer gel electrolyte or liquid electrolyte, showed an enhanced stability. Concomitantly, the formulation of the polymer gel electrolyte was also addressed and had to be tuned to allow an easier filling of the modules.