Nano-architected/assembled solar electricity cell

• US 6,852,920 B2
• Filed: 12/11/2002
• Issued: 02/08/2005
• Est. Priority Date: 06/22/2002
• Status: Expired due to Fees

• Current Assignee: Aeris Capital Sustainable IP, Ltd.
• Original Assignee: Nanosolar Incorporated
• Inventors: Roscheisen, Martin R., Sager, Brian M.
• Primary Examiner(s): DIAMOND, ALAN D
• Application Number:
  US10/319,406
• Publication Number:
  US 20040250848A1
• Time in Patent Office: 790 Days
• Field of Search: 136/263, 136/255, 136/256, 257/40, 257/465, 257/466, 257/464, 257/461, 438/82, 438/71, 438/88, 438/57
• US Class Current: 136/263
• CPC Class Codes: B82Y 10/00 Nanotechnology for information processing, storage or transmission, e.g. quantum computing or single electron logic
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: H01G 9/2031 comprising titanium oxide, e.g. TiO2 H01G9/2036 takes precedence
• CPC Class Codes: H10K 30/15 Sensitised wide-bandgap semiconductor devices, e.g. dye-sensitised TiO2 photo-electrochemical devices comprising a liquid electrolyte or a solid electrolyte H01G9/20
• CPC Class Codes: H10K 30/30 comprising bulk heterojunctions, e.g. interpenetrating networks of donor and acceptor material domains
• CPC Class Codes: H10K 30/35 comprising inorganic nanostructures, e.g. CdSe nanoparticles
• CPC Class Codes: H10K 30/50 Photovoltaic [PV] devices
• CPC Class Codes: H10K 71/191 characterised by provisions for the orientation or alignment of the layer to be deposited
• CPC Class Codes: H10K 85/111 comprising aromatic, heteroaromatic, or aryl chains, e.g. polyaniline, polyphenylene or polyphenylene vinylene
• CPC Class Codes: H10K 85/113 Heteroaromatic compounds comprising sulfur or selene, e.g. polythiophene
• CPC Class Codes: H10K 85/211 Fullerenes, e.g. C60
• CPC Class Codes: H10K 85/60 Organic compounds having low molecular weight H10K85/10 - H10K85/50 take precedence
• CPC Class Codes: Y02E 10/549 Organic PV cells
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y10S 977/948 Energy storage/generating using nanostructure, e.g. fuel cell, battery

Abstract

Nano-architected/assembled solar cells and methods for their manufacture are disclosed. The solar cells comprise oriented arrays of nanostructures wherein two or more different materials are regularly arrayed and wherein the presence of two different materials alternates. The two or more materials have different electron affinities. The two materials may be in the form of matrixed arrays of nanostructures. The presence of the two different materials may alternate within distances of between about 1 nm and about 100 nm. An orientation can be imposed on the array, e.g. through solution deposition surfactant templation or other methods.

Claims

1. A solar cell device, comprising:

two or more materials having different electron affinities, the solar cell device being characterized by an architecture wherein the two or more materials are regularly arrayed and wherein the presence of the two or more materials alternates within distances of between about 1 nm and about 100 nm, wherein the architecture is characterized by a mesoporous template having a conducting or semiconducting inorganic media containing pores, wherein the pores are filled with a conducting or semiconducting polymer material having a different electron affinity than the surrounding conducting or semiconducting inorganic media.

2. The solar cell of claim 1 wherein the presence of the two or more materials alternates within distances of between about 1 nm and about 25 nm.

3. The solar cell of claim 2 wherein the presence of the two or more materials alternates within distances of between about 5 nm and about 15 nm.

4. A solar cell device, comprising:

two or more materials having different electron affinities, the solar cell device being characterized by an architecture wherein the two or more materials are regularly arrayed and wherein the presence of the two or more materials alternates within distances of between about 1 nm and about 100 nm, wherein the two or more materials include C₆₀ and a conducting or semiconducting polymer material.

5. A solar cell comprising one or more regularly structured nanoscale arrays of nanostructures embedded within a matrix of conducting or semiconducting inorganic media, wherein the nanostructures have a different electron affinity than the conducting or semiconducting inorganic media, wherein the arrays of nanostructures embedded within the matrix are characterized by an architecture with a mesporous template made of conducting or semiconducting inorganic media containing pores, wherein the pores are filled with conducting or semiconducting polymer materials, wherein the conducting or semiconducting polymer materials have a different electron affinity than the surrounding inorganic conducting or semiconducting media.

6. The solar cell of claim 5 wherein a separation distance between adjacent nanostructures in the one or more regularly structured nanoscale arrays is between about 1 and about 100 nm.

7. The solar cell of claim 6 wherein the separation distance between adjacent nanostructures in the one or more regularly structured nanoscale arrays is between about 1 nm and about 25 nm.

8. The solar cell of claim 7 wherein the separation distance between adjacent nanostructures in the one or more regularly structured nanoscale arrays is between about 5 nm and about 15 nm.

9. The solar cell of claim 5 wherein the arrays of nanostructures include an array of spheres or spheroidal objects arranged in a regular matrix, or an array of ovoid or elongate objects arranged in a regular matrix.

10. The solar cell of claim 5, wherein two or more different arrays interdigitate within the same layer.

11. The solar cell of claim 5 wherein the pores have diameters between about 5 nm and about 50 nm.

12. The solar cell of claim 11 wherein the mesoporous template is fabricated with a conducting or semiconducting polymer embedded within the template.

13. The solar cell of claim 5 wherein the conducting or semiconducting polymeric materials include a material chosen from the group of poly(phenylene) and derivatives thereof, poly(phenylene vinylene) and derivatives thereof, poly(2-methoxy-5-(2-ethyl-hexyloxy)-1,4-phenylene vinylene (MEH-PPV), poly(para-phenylene vinylene) (PPV)), poly(thiophene) and derivatives thereof, regioregular poly(3-octylthiophene-2,5,-diyl), regiorandom poly(3-octylthiophene-2,5,-diyl), regioregular poly(3-hexylthiophene-2,5-diyl), regiorandom poly(3-hexylthiophene-2,5-diyl), poly(thienylenevinylene) and derivatives thereof, poly(isothianaphthene) and derivatives thereof, organometallic polymers, polymers containing perylene units, and poly(squaraines) and their derivatives.

14. The solar cell of claim 5 wherein the conducting or semiconducting polymeric materials include P3HT (poly(3-hexylthiophene)).

15. The solar cell of claim 5 wherein the mesoporous template is fabricated with a pigment or dye embedded within the template.

16. The solar cell of claim 15, wherein the pigment or dye includes a material chosen from the group of organic pigments or dyes, azo-dyes having azo chromofores (—

N═

N—

) linking aromatic groups, phthalocyanines including metal-free phthalocyanine(HPc)perylenes, naphthalocyanines, squaraines, merocyanines and their respective derivatives, poly(silanes), poly(germinates), 2,9-Di(pent-3-yl)-anthra[2,1,9-def;

6,5,10-d′

e′

f′

]diisoquinoline-1,3,8,10-tetrone, and 2,9-Bis-(1-hexyl-hept-1-yl)-anthra[2,1,9-def;

6,5,10-d′

e′

f′

]diisoquinoline-1,3,8,10-tetrone.

17. The solar cell of claim 5, wherein the nanostructures are present in one or more size ranges.

18. The solar cell of claim 17 wherein the nanostructures are present in one or more layers.

19. The solar cell of claim 5 wherein the nanostructures further include C₆₀.

20. A method for making solar cells, comprising:

imposing an orientation on an array of two or more materials having different electron affinities, such that the two or more materials are regularly arrayed and the presence of the two or more materials alternates within distances of between about 1 nm and about 100 nm, wherein the two or more materials are characterized by an architecture with a mesoporous template having a conducting or semiconducting inorganic media containing pores, wherein the pores are filled with a conducting or semiconducting polymer material having a different electron affinity than the surrounding conducting or semiconducting inorganic media.

21. The method of claim 20 wherein the presence of the two or more materials alternates within distances of between about 1 nm and about 25 nm.

22. The method of claim 21 wherein the presence of the two or more materials alternates within distances of between about 5 nm and about 15 nm.

23. The method of claim 22 wherein the two or more materials include C₆₀ and a conducting or semiconducting polymer material.

24. The method of claim 20 wherein imposing the orientation on the array includes solution deposition of one of the two or more materials into a surfactant-templated, high-porosity polymeric mold structure.

25. The method of claim 20 wherein imposing the orientation on the array includes electrodeposition of one of the two or more materials into a surfactant-templated, high-porosity polymeric mold structure.

26. The method of claim 20 wherein imposing the orientation on the array includes using an external ordering field.

27. The method of claim 26 wherein the external ordering field is an electric field.

28. The method of claim 20, wherein imposing the orientation on the array includes forming a mesoporous template having an array of pores.

29. The method of claim 28 wherein forming the mesoporous template includes pre-depositing a layer of surfactant-templated, high-porosity thin films.

30. The method of claim 29, wherein the layer of surfactant-templated, high-porosity thin films act as a mold for the deposition of an active solar cell material.

31. The method of claim 29 wherein pre-depositing a layer of surfactant-templated, high-porosity thin films includes depositing one or more reactants by an inkjet deposition.

32. The method of claim 29 wherein the surfactant-templated, high-porosity thin films include one or more luminscent dyes.

33. The method of claim 32, wherein the dyes may absorb photons that are at wavelengths unsuited for conversion with the solar cells and reradiate energy at wavelengths more suitable for efficient conversion to solar power.

34. The method of claim 28, wherein forming the mesoporous-template includes using one or more techniques selected from the following group:

intercalation and/or grafting of organic or polymeric molecules within a mineral lamellar network,

synthesis by electrocrystallisation of hybrid molecular assemblies,

impregnation of preformed inorganic gels, synthesis from heterofunctional metallic alkoxides or silsesquioxannes,

synthesis through the connection of well defined functional nanobuilding blocks,

templated growth of inorganic or hybrid networks using organic molecules and macromolecules including surfactants, amines, alkyl ammonium ions, or amphiphilic molecules, as structure directing agents, and

templated growth with nanoparticles followed by removal of the nanoparticles and bioengineered self-assembly.

35. The method of claim 28 wherein forming the mesoporous template includes bioengineered self-assembly.

36. The method of claim 35, wherein the bioengineered self-assembly includes using a one-, two-, or three-dimensional protein array to serve as a scaffolding template for the ordered deposition/application of metals, metal oxides, and/or semiconducting materials, alone or in blends.

37. The method of claim 36 wherein each protein molecule in the one-, two-, or three-dimensional protein array is attached to at least one nanostructured metal or metal oxide particle.

38. The method of claim 37 further comprising destroying the protein array after metal or metal oxide deposition has occurred.