Method for manufacturing solar cells
First Claim
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1. A method for manufacturing at least one solar cell, the method comprising the sequential steps of:
- (a) providing at least two substrates;
(b) at least partially forming at least one cell by applying portions of a low melting point gasket material to some regions of a substrate and applying portions of a high melting point gasket material to other regions of a substrate so that the low melting point gasket material defines a first portion of a perimeter of the cell and the high melting point gasket material defines a remaining second portion of the perimeter of the cell;
(c) bringing the two substrates together;
(d) activating the lower melting point gasket material to seal the first portion of the perimeter of the cell such that the lower melting point gasket material seals between the two substrates;
(e) filling the at least one cell defined by the gasket materials with an electrolyte by passing the electrolyte through the unactivated second portion of the perimeter of the cell defined by the high melting point gasket material; and
(f) activating the higher melting point gasket material to seal the second portion of the perimeter of the cell such that the higher melting point gasket material seals between the two substrates.
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Abstract
Methods and materials used to manufacture a series of substantially identical solar cells which then can be assembled into arrays of various designs, as required, to achieve the desired electrical output. The invention is described with reference to producing dye solar cells.
70 Citations
22 Claims
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1. A method for manufacturing at least one solar cell, the method comprising the sequential steps of:
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(a) providing at least two substrates; (b) at least partially forming at least one cell by applying portions of a low melting point gasket material to some regions of a substrate and applying portions of a high melting point gasket material to other regions of a substrate so that the low melting point gasket material defines a first portion of a perimeter of the cell and the high melting point gasket material defines a remaining second portion of the perimeter of the cell; (c) bringing the two substrates together; (d) activating the lower melting point gasket material to seal the first portion of the perimeter of the cell such that the lower melting point gasket material seals between the two substrates; (e) filling the at least one cell defined by the gasket materials with an electrolyte by passing the electrolyte through the unactivated second portion of the perimeter of the cell defined by the high melting point gasket material; and (f) activating the higher melting point gasket material to seal the second portion of the perimeter of the cell such that the higher melting point gasket material seals between the two substrates. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22)
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Specification