PHOTOVOLTAIC APPARATUS AND METHOD

Abstract

Embodiments of the invention are directed to a method of producing a photovoltaic apparatus. The method includes the steps of providing a substrate; forming a first conducting electrode layer on the substrate; forming a first charge selective layer at least partially over the first conducting electrode layer; forming a photoactive layer at least partially over the first charge selective layer; forming a second charge selective layer at least partially over the photoactive layer; removing portions the formed layers at predetermined intervals along the substrate creating discrete layer sections partially forming individual photovoltaic modules; and printing a second conducting electrode layer partially over the discrete layer sections and substrate to form a plurality of photovoltaic modules, each photovoltaic module having first and second module terminals, a plurality of inter-module rails, each inter-module rail being located between adjacent photovoltaic modules, a first bus bar extending along one side of the photovoltaic modules, and a second bus bar extending along an opposite side of the photovoltaic modules.

Claims

1. A method of producing a photovoltaic apparatus, wherein the method includes providing a substrate; forming a first conducting electrode layer on the substrate; forming a photoactive layer at least partially over the first conducting electrode layer; forming a charge selective layer at least partially over the photoactive layer; removing portions of the formed layers at predetermined intervals along the substrate creating discrete layer sections partially forming individual photovoltaic modules; and printing a second conducting electrode layer partially over the discrete layer sections and substrate to form a plurality of photovoltaic modules, each photovoltaic module having first and second module terminals, a plurality of inter-module rails, each inter-module rail being located between adjacent photovoltaic modules, a first bus bar extending along one side of the photovoltaic modules, and a second bus bar extending along an opposite side of the photovoltaic modules.

2. The method of claim 1, wherein each of the formed layers comprise a plurality of stripes, each one of the stripes forming part of a printed photovoltaic cell, and wherein each photovoltaic module includes a plurality of photovoltaic cells between the first and second module terminals such that the plurality of photovoltaic cells are electrically connected in series.

3. The method of claim 1, wherein the first conducting electrode layer is formed using a dispenser via a coating process, the first conducting electrode layer including a plurality of continuous stripes, the method further including moving the substrate relative to the dispenser along a substrate travel direction such that the continuous stripes are parallel to the substrate travel direction.

4. The method of claim 1, wherein the photoactive layer is formed using a dispenser via a coating process, the photoactive layer including a plurality of continuous stripes, the method further including moving the substrate relative to the dispenser along a substrate travel direction such that the continuous stripes are parallel to the substrate travel direction.

5. The method of claim 1, wherein the charge selective layer is formed using a dispenser via a coating process, the photoactive layer including a plurality of continuous stripes, the method further including moving the substrate relative to the dispenser along a substrate travel direction such that the continuous stripes are parallel to the substrate travel direction.

6. The method of claim 1, wherein printing a second conducting electrode layer includes screen printing the second conducting electrode layer.

7. The method of claim 1, wherein at least one of the plurality of inter-module rails is formed with a linkable gap.

8. The method of claim 7, further including selectively connecting adjacent photovoltaic modules by applying a conductive material over the at least one linkable gap.

9. The method of claim 1, further including selectively connecting one of the first or second module terminals of a photovoltaic module to one of the first and second bus bars by application of a conductive material between the respective first or second module terminal and the respective first or second bus bar.

10. The method of claim 1, further including selectively disconnecting adjacent photovoltaic modules by creating a gap in a respective inter-module rail.

11. The method of claim 1, wherein one or more of the first conducting electrode layer, the photoactive layer, and the charge selective layer is formed using one or more dispensers via a coating process, each of the formed layers including a plurality of stripes, the method further including moving the substrate relative to the one or more dispensers along a substrate travel direction such that the stripes are formed along the substrate travel direction, and wherein the first and second bus bars are parallel to the substrate travel direction.

12. The method of claim 1, further including selectively connecting a photovoltaic module to an adjacent photovoltaic module by application of a conductive material over a linkable gap in a respective inter-module rail between the photovoltaic module and the adjacent photovoltaic module, and selectively connecting one of the first and second module terminals of a photovoltaic module to, or disconnecting one of the first and second module terminals of a photovoltaic module from, one of the first and second bus bars, so as to selectively connect the plurality of photovoltaic modules electrically in series or in parallel, or a combination thereof.

13. The method of claim 1, wherein the photovoltaic apparatus is a printed solar film.

14. The method of claim 13, wherein the printed solar film is produced via a roll-to-roll printing process.

15. The method of claim 1, wherein removing portions of the formed layers includes removing portions of the formed layers via scratching or delamination processes, or a combination thereof.

16. A method of printing solar film, wherein the method includes providing a flexible carrier substrate; printing a plurality of stacked layers on the flexible carrier substrate, removing portions of the stacked layers at predetermined intervals along the carrier substrate creating discrete layer sections partially forming individual photovoltaic modules; and printing a conducting electrode layer partially over the discrete layer sections and flexible carrier substrate to form the photovoltaic modules.

17. The method of claim 16, further including selectively connecting the photovoltaic modules electrically in series or in parallel, or a combination thereof.

18. The method of claim 16, wherein printing the plurality of stacked layers includes dispensing, via one or more dispensers, each of the stacked, the method further including moving the flexible carrier substrate relative to the one or more dispensers in a substrate travel direction such that the stacked layers are printed parallel to the substrate travel direction.

19. The method of claim 18, including printing first and second bus bars in a direction parallel to the substrate travel direction.

20. The method of claim 16, wherein printing a conducting electrode layer includes screen printing the conducting electrode layer to form the photovoltaic modules, an inter-module rail between adjacent photovoltaic modules, and first and second bus bars, and wherein each photovoltaic module includes a plurality of photovoltaic cells electrically connected in series.

21. The method of claim 16, further including printing an inter-module rail between each adjacent photovoltaic module on the carrier substrate, printing first and second bus bars on the carrier substrate, selectively applying conductive material at predetermined locations on the carrier substrate so as to selectively connect a photovoltaic module to an adjacent photovoltaic module, or selectively connect a photovoltaic module to the first or second bus bar such that the photovoltaic modules can be selectively electrically connected in series or parallel, or a combination thereof.

22. The method of claim 16, further including printing an inter-module rail between each adjacent photovoltaic module on the carrier substrate, printing first and second bus bars on the carrier substrate, selectively removing conductive material from predetermined locations on the carrier substrate so as to selectively disconnect a photovoltaic module from an adjacent photovoltaic module, or selectively disconnect a photovoltaic module from the first or second bus bar such that the photovoltaic modules can be selectively electrically connected in series or in parallel, or a combination thereof.

23. A method of printing solar film, wherein the method includes providing a flexible carrier substrate; printing a plurality of printed photovoltaic modules on the flexible carrier substrate, each module including first and second module terminals, a plurality of printed photovoltaic cells between the first and second module terminals such that each photovoltaic cell is electrically connected in series with an adjacent photovoltaic cell; printing first and second bus bars along the flexible carrier substrate, and defining a plurality of selectively configurable junctions at predetermined locations on the solar film, one or more of the selectively configurable junctions being configurable during manufacture and prior to application of a protective coating so as to enable a photovoltaic module to selectively connect to or disconnect from an adjacent photovoltaic module, and enable a module terminal to selectively connect to or disconnect from one of the first and second bus bars.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0136] Specific embodiments of the present invention will now be described by way of example and with reference to the accompanying drawings. It is to be understood that the embodiments are given by way of illustration only and the invention is not limited by this illustration. In the drawings:

[0137] FIG. 1A shows an example of a PV module with four cells connected in series.

[0138] FIG. 1B shows a cross-section of a PV module.

[0139] FIG. 1C shows details of structure of a PV cell.

[0140] FIG. 2A shows an example of bidirectional infinitely interconnected PV modules.

[0141] FIG. 2B show an example of unidirectional infinitely interconnected PV modules.

[0142] FIG. 3 shows an example of a PSF layout in a hybrid design with three series connected modules.

[0143] FIG. 4 shows a PSF layout in a hybrid design configured with two channels.

[0144] FIG. 5A shows a PSF layout with linkable gaps for inter-module rails and between modules and bus bars.

[0145] FIG. 5B shows the layout of FIG. 5A after the gaps have been bridged.

[0146] FIGS. 6A-6D shows examples of linkable gaps that include a simple line or complex shapes.

[0147] FIG. 7A shows a PSF layout with severable links for inter-module rails and between modules and bus bars.

[0148] FIG. 7B shows the layout of FIG. 7A after the links have been severed.

[0149] FIG. 8A shows a PSF layout with linkable gaps for inter-module rails.

[0150] FIG. 8B shows an alternative PSF layout with linkable gaps between modules, inter-module rails and bus bars.

[0151] FIG. 8C shows the layout of FIG. 8B after the gaps have been bridged or connected.

[0152] FIG. 9A shows a PSF layout with linkable gaps for series connections between leading module L and trailing module T.

[0153] FIG. 9B shows an alternative PSF layout to FIG. 9A, also having linkable gaps for series connections between leading module L and trailing module T.

[0154] FIG. 10A shows an example of a photovoltaic module or unit comprising three electrically connected modules according to one embodiment.

[0155] FIG. 10B shows an example of a photovoltaic module or unit comprising four electrically connected modules according to another embodiment.

[0156] FIG. 11 shows a schematic diagram illustrating steps in a manufacturing process for a Printed Solar Film according to one embodiment of the present invention.

[0157] FIG. 12A illustrates a plan view of a section of a substrate of a photovoltaic apparatus carrying each of the first conducting electrode layer 11, first charge selective layer 12, the photoactive layer 13 and the second charge selective layer 14 after a coating process.

[0158] FIG. 12B illustrates the substrate shown in FIG. 12A after the relevant portions of each layer 11 to 14 are removed via an etching process so as to form the basis for individual photovoltaic modules.

[0159] While the present invention is susceptible to various modifications and alternative forms, specific embodiments have been shown by way of examples in the drawings and will be described in detail herein. It should be understood, however, that the invention is not intended to be limited to the particular forms disclosed. Rather, the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.

DESCRIPTION OF PREFERRED EMBODIMENTS

Definitions

Photovoltaic Cell

[0160] In the context of the present invention, the term photovoltaic cell denotes a unit comprising one or more elements that convert light that impinges on its surface and upon being absorbed is converted into electrical energy in the form of a current at a given voltage in an external circuit.

Photovoltaic Module

[0161] In the context of the present invention, the term photovoltaic module denotes a module comprising a plurality of photovoltaic cells.

Module Terminal

[0162] In the context of the present invention, the term module terminal denotes an output terminal of a photovoltaic module. A photovoltaic module may comprise two module terminals e.g. a positive terminal and a negative terminal. In the photovoltaic module according to the present invention, the photovoltaic module comprises one positive module terminal and one negative module terminal between which the photovoltaic cells are arranged.

Printed

[0163] In the context of the present invention, the term printed denotes any kind of transfer process, such as rotary screen printing, flat bed screen printing, gravure printing, flexographic printing, inkjet printing, slot-die coating, knife coating, blade coating, bar coating and coil coating.

Web

[0164] In the context of the present invention, the term web denotes a thin sheet of a material such as metal foil or plastics foil. In one embodiment, the web may have a thickness which is below 1 mm, including below 0.9 mm, or below 0.8 mm, or below 0.75 mm, or below 0.7 mm, or below 0.6 mm, or below 0.5 mm, or below 0.4 mm, or below 0.3 mm, or below 0.25 mm, or below 0.2 mm, or below 0.1 mm.

[0165] In one embodiment, the web may be made of a bendable material and may have a bend radius below 1000 mm, including below 500 mm, or below 250 mm, or below 125 mm, or below 100 mm, or below 75 mm, or below 50 mm, or below 40 mm, or below 30 mm, or below 25 mm, or below 20 mm, or below 15 mm, or below 10 mm, or below 5 mm.

Bend Radius

[0166] In the context to the present invention, the term bend radius denotes a minimum measure, which is measured inside a curvature, by which a material may be bent without breaking, being damaged or have a shortened life. In one embodiment, the material may be bent to this radius without being plastically deformed, in other words the material may be only elastically deformed when bent to this radius. Thus, it may be appreciated that the smaller the bend radius of a material is, the more flexible and bendable the material is. Similarly it may be appreciated that the larger the bend radius is, the stiffer the material is.

[0167] One way of testing the bend radius of the web may be to provide a cylinder with a radius corresponding to the bend radius. Subsequently, the web may be bent about the cylinder. As an example a cylinder with a radius of 25 mm may be provided and subsequently, the web may be bent about the cylinder. Finally, the photovoltaic module may be tested so as to determine whether it is still functioning, i.e. capable of generating the same amount of electricity as a web which has not been bent.

Organic

[0168] In the context of the present invention, the term organic denotes a material that comprises molecules built through carbon-carbon bonds that may be saturated or unsaturated and that can be connected in a conjugated fashion to convey semiconducting properties. The organic materials may include one or more other elements such as hydrogen, nitrogen, oxygen, sulphur, selenium, phosphorous and metal ions.

[0169] The present invention may provide an interconnection method for printed solar films (PSFs) including solution processed solar cells produced by printing on flexible substrates. Solution processed solar cells including organic solar cells, organic-inorganic hybrid perovskite solar cells; inorganic nano particle based solar cells are typically fabricated on transparent conducting electrodes (TCEs).

[0170] FIG. 1a shows an example of a TCE based PV module with four cells in a series connection and FIG. 1b shows a cross-section of the PV module. In a research laboratory, devices are typically fabricated as small area single cells. In contrast, series-interconnection of cells is required for a large area device due to limited conductivity of TCEs. Losses originating from high resistivity, so called ohmic losses, of TCEs may become significant when cell width is more than centimetre scale. Therefore, a striped pattern design as shown in FIG. 1A is typically used to fabricate a large area TCE based device.

[0171] FIG. 1C shows details of the structure of a PV cell in cross-section. The cross-section includes substrate 10, conducting electrode 11, charge selective layer 12, photoactive layer 13, charge selective layer 14 and conducting electrode 15.

[0172] Substrate 10 may comprise a plastic material such as PET, PEN and polyimides metal foils with insulating coating and flexible glasses. Conducting electrode 11 typically comprises Indium doped tin oxide (ITO). Alternatively, other metal oxides, conducting polymers, metal nanowire and composite (metal grid with other conducting materials) may be used. In the case of a top illumination device with a transparent top electrode, conducting electrode 11 may include opaque metals.

[0173] Charge selective layer 12 (also called a buffer layer or charge (electron, hole) transport layer) is optional as the device may operate without layer 12. Materials may typically include metal oxides or organic semiconductors. Double or triple layers and/or composite materials may also be used.

[0174] Conducting electrode 15 may comprise a similar material as is used for conducting electrode 11. When a TCE is used for conducting electrode 11, conducting electrode 15 may comprise an opaque conductor.

[0175] The module design is mainly useful when the application area is small (typically smaller than A3 size) and is typically used in sheet form. For large area applications, solar cells are traditionally produced on long films in roll form via a roll-to-roll process. The module pattern may be repeated and series-connected along a processing direction.

[0176] As described above, a practical interconnection method has been developed that uses an infinite interconnection of cells referred as an infinity design to produce a relatively high voltage without suffering ohmic losses due to high current from a large cell area. Although the infinity design is practical and useful, there are limitations in real world applications as discussed above.

[0177] To address the limitations of conventional sheet module and infinity designs the present invention proposes a hybrid interconnection design. The proposed hybrid design comprises repeated unit modules, inter-module rails and parallel bus bars as described below with reference to FIGS. 3 to 7.

[0178] FIG. 3 shows an example of a PSF layout in a hybrid design 30 with three modules 31-33 connected in series via inter-module rails 34 to form a minor unit wherein minor units are parallel-connected to bus bars 35, 36 to form a major unit. A desired output voltage between bus bars 35, 36 may be determined by selecting the number of series-connected modules in a repeating minor unit. The leading and trailing modules of each minor unit may be connected to bus bars 35, 36 so that power may be collected at any point on bus bars 35, 36. The hybrid-interconnection design may be used with multi-channel designs such as the bidirectional design shown in FIG. 2A.

[0179] Each of the three photovoltaic modules 31-33 includes a plurality of photovoltaic cells 37 connected in series. For illustrative purposes, 9 photovoltaic cells are shown in each photovoltaic module. However, in practice, any suitable number of photovoltaic cells can be included in each photovoltaic module. Typically, 5 to 20 photovoltaic cells 37 are included in each module 31-33, for example if the with substrate 38 has width (W) of roughly 30 cm. In one embodiment, 5 photovoltaic cells 37 are included in each module 31-33. In another embodiment, 16 photovoltaic cells 37 are included in each module 31-33. In a further embodiment, 20 photovoltaic cells 37 are included in each module 31-33. In other embodiments, more photovoltaic cells 37 may be included in each module 31-33, particularly if the width (W) of the substrate 38 is increased.

[0180] It can be more clearly appreciated from at least FIG. 3 that embodiments of the present invention advantageously allows the connections between the photovoltaic modules to be selectively configured in a flexible manner so as to provide any custom output in order to suit any application. Due to the size, arrangement and configuration of the photovoltaic cells and modules, it has been found that selectively configuring the series/parallel connections between the photovoltaic modules using, for example, the inter-module rails and junctions would be much easier than attempting to achieve a similar outcome by altering connections between individual photovoltaic cells.

[0181] FIG. 4 shows a PSF layout in a hybrid design 40 configured with two channels 41, 42. The hybrid design may be achieved by printing rails and/or bus bars and connections and/or junctions by any known industrial or mass manufacturing method such as screen printing and modifying the mass-produced connections or junctions using various methods as described below.

[0182] In some embodiments small gaps may be provided in inter-module connections and between unit modules and bus bars, which may be easy to bridge, link or fill. The gaps may be bridged, linked or filled with conductive ink using various tools such as solution dispenser, stamp, slot die, spray, brush and ink jet printing. The gaps may also be bridged or linked via conductive tapes and/or stickers.

[0183] FIG. 5A shows a PSF layout 50 with linkable gaps 51 associated with inter-module rails 52 and linkable gaps 53, 54 between modules 55 and bus bars 56, 57.

[0184] Gaps 51 are electrically linkable to the associated module terminal when the associated module is to be connected in series to the adjacent module.

[0185] Gaps 53 are electrically linkable to bus bar 56 when the associated module is to be connected in parallel to an adjacent module.

[0186] Gaps 54 are electrically linkable to bus bar 57 when the associated module is to be connected in parallel to the adjacent module. In each case the link may be made via a conductive paste or the like.

[0187] FIG. 5B shows the same layout 50 after gaps 51, 53, 54 have been bridged or connected via a conductive paste. After gaps 51, 53, 54 are bridged; layout 50 forms a minor unit 58 comprising 3 modules connected in series as shown in the example of FIG. 5A. Minor units 58 may be repeated along the carrier substrate at least once to form m minor units of 3 modules each wherein m is an integer. The m minor units of n modules may be electrically connected in parallel to form a major unit of 3?m modules.

[0188] As shown in FIGS. 6A-6D each gap 51, 53, 54 may include a simple straight line 60 (FIG. 6A) or it may include more complex shapes 61-63 (FIGS. 6B to 6D) to better accommodate error tolerance in connecting or bridging the gaps. Each gap may be bridged or connected via a conductive paste or the like.

[0189] In other embodiments all photovoltaic modules may initially be connected via severable links and also parallel connected to bus bars. Connections between inter-module rails and bus bars may be subsequently disconnected or severed in any number of ways to determine the number of series-connected unit modules in a repeating unit. The connections may be severed via laser scribing, mechanical scribing and/or chemical etching.

[0190] FIG. 7A shows a PSF layout 70 with severable links 71 associated with inter-module rails 72 and severable links 73, 74 between modules 75 and bus bars 76, 77.

[0191] Links 71 are maintained when the associated module is to be connected in series to the adjacent module. Links 71 are severed when the associated module is to be connected in parallel with the adjacent module.

[0192] Links 73, 74 are maintained when the associated module is to be connected in parallel to an adjacent module. Links 73, 74 are severed when the associated module is to be connected in series to the adjacent module.

[0193] FIG. 7B shows the same PSF layout 70 after links 71, 73, 74 have been severed. After links 71, 73, 74 have been severed; layout 70 forms a minor unit 78 comprising three modules connected in series as shown in the example of FIG. 7B. Minor units 78 may be repeated along the carrier substrate at least once to form m minor units of 3 modules each wherein m is an integer. The m minor units of n modules may be electrically connected in parallel to form a major unit of 3?m modules.

[0194] FIG. 8A shows a PSF layout 80 comprising a plurality of modules 81 with linkable gaps 82 associated with inter-module rails 83. Gaps 82 are electrically linkable at least when the associated module/unit of modules is to be connected in series to the adjacent module/unit of modules.

[0195] FIG. 8B shows an alternative PSF layout 80 comprising a plurality of modules with linkable gaps 82 associated with inter-module rails 83, linkable gaps 84, 85 associated with module terminals 86, 87 and linkable gaps 88, 89 between module terminals 86, 87 and bus bars 90, 91. Gaps 82 are electrically linkable at least when the associated module/unit of modules is to be connected in series to the adjacent module/unit of modules. Gaps 84, 85 associated with module terminals 86, 87 are electrically linkable at least when the associated module is to be connected in parallel to an adjacent module.

[0196] Gaps 88 are electrically linkable to bus bar 90 at least when an associated leading module or unit of modules is to be connected in parallel to the adjacent module/unit of modules. Similarly Gaps 89 are electrically linkable to bus bar 91 at least when the associated trailing module/unit of modules is to be connected in parallel to the adjacent module/unit of modules. In each case the link may be made via a conductive paste, a conductive ink or a conductive tape or the like.

[0197] FIG. 8C shows the same layout 80 after gaps 82, 84, 85, 88 and 89 have been bridged or connected on demand via a conductive paste (or left disconnected as the case may be). After the gaps are bridged (or left disconnected); layout 80 forms minor units 92, 93 each comprising two modules connected in series. Minor units 92, 93 may be repeated along the carrier substrate to form m minor units of two modules each wherein m is an integer. The m minor units of n modules may be electrically connected in parallel to form a major unit of two X m modules.

[0198] FIG. 9A shows a PSF layout 80 comprising a plurality of modules 81 with linkable gaps 82 associated with inter-module rails 83, and linkable gaps 88, 89 between module terminals 86, 87 and bus bars 90, 91, for series connections between leading module L and trailing module T.

[0199] FIG. 9B shows an alternative PSF layout 80 comprising a plurality of modules 81 with linkable gaps 82 between module terminals 86, 87, and linkable gaps 88, 89 between module terminals 86, 87 and bus bars 90, 91 for series connections between leading module L and trailing module T.

[0200] FIG. 10A shows an example PSF layout 80 of a photovoltaic module or unit of three electrically interconnected photovoltaic modules. A unit of three modules 81 is shown with a leading unit L1 connected to bus bar 90 via junction 88 and a trailing unit T connected to bus bar 91 via junction 89, with modules L1, N and T connected in series to one another via junctions 82. Other junctions 84, 85, 88 and 89 between L1 and T remain disconnected. L2 will form part of a separate unit.

[0201] FIG. 10B shows an example PSF layout 80 of a photovoltaic module or unit comprising four electrically connected modules. A unit of four modules 81 is shown with a leading unit L1 connected to bus bar 90 via junction 88 and a trailing unit T connected to bus bar 91 via junction 89. Modules L1 and N1, and N2 and T are connected to each other in parallel via junctions 84 and 85. Modules N1 and N2 are connected to each other in series via junction 82. Other junctions 82, 84, 85, 88 and 89 between L1 and T remain disconnected.

[0202] In further embodiments the photovoltaic modules may be connected via a combination of methods including linkable gaps and severable links as described above with reference to FIGS. 5-10.

[0203] Compared to a conventional module sheet, the present invention may allow relatively large area devices to be produced. Output voltage of large area solar cells may be set on-demand after or during a manufacturing process.

[0204] In a large area installation, output voltage may be set to a safe level and/or may be compatible with any inverter system. In a large area installation, printed solar films may be cut to a desired length (with limited freedom or anywhere with some area wastage when the middle of a repeating unit is cut) regardless of required output voltage.

[0205] Energy may be collected from anywhere on the bus bars. Interconnections between PSFs may be made at any point for a wide area application such as a multiple PSFs installation in a parallel direction.

[0206] The photovoltaic apparatus and method of the present invention may be particularly suitable for use with solution processed solar cells on flexible substrates.

[0207] A method 110 of manufacturing a printed solar film (PSF) according to an embodiment of the invention will now be described with reference to FIG. 11. The method 110 can be used to form each of the appropriate layers 11 to 15 formulating the photovoltaic cells as more clearly shown in FIG. 1C which collectively make up the photovoltaic modules and photovoltaic apparatus as previously described with reference to FIGS. 3 to 10B.

[0208] During a first step 112, a carrier substrate 10 (such as a flexible ITO substrate) is provided. For illustrative purposes, the substrate 10 in FIG. 11 moves in a web direction (also referred to herein as a substrate travel direction) as illustrated by arrow 128 in FIG. 11 during manufacture. The first conducting electrode layer 11 is applied via a coating process to the substrate 10. A dispenser 126 is used to apply the first conducting electrode layer 11 via the coating process. Preferably, an indium-tin-oxide (ITO) based conductive material is used for the first conducting electrode layer. Moreover, the first conducting electrode layer 11 is formed with a thickness range of roughly 100-300 nm.

[0209] Unlike some printing processes, this coating process advantageously allows accurate control of the thickness of the applied layers. In particular, the coating process allows uniform layers to be applied at the desired thickness. In addition, the coating process allows each layer to be created continuously as the substrate moves relative to a dispenser, which allows for greater efficiency (e.g. when compared to various printing processes).

[0210] Typically, in printing processes, droplets of printing ink are dispensed on a substrate. Such printing processes can create uneven thicknesses, and occasionally gaps (also known as pinholes) in the printed layer. In addition, the thickness of the printed layer is difficult to accurately control, particularly when a high level of accuracy and uniformity is required in the thickness of the printed layer.

[0211] During a second step 114, the first charge selective layer 12 is applied via the same coating process over the substrate 10 and partially covering the first conducting electrode layer 11. Preferably, first charge selective layer 12 is formed with a thickness range of roughly 10-100 nm.

[0212] During a third step 116, the photoactive layer 13 is also applied via the same coating process over the substrate 10 and partially covering first change selective layer 12. Preferably, photoactive layer 13 is formed with a thickness range of roughly 100-500 nm.

[0213] Whilst not shown in FIG. 11, the second charge selective layer 14 can also be applied via the same coating process over substrate 10 and partially covering the photoactive layer 13. Preferably, second charge selective layer 14 is formed with a thickness range of roughly 10-500 nm.

[0214] Whilst it is preferable to use a coating process to apply each of the layers 11 to 14 for each of thickness and quality control, a sufficient level of quality may be achieved using certain printing processes. For example, the charge selective layer has reasonable conductivity and it is more thickness tolerant. Accordingly, methods such as rotary screen printing may be used to form the charge selective layer.

[0215] During an forth step 118 (also not shown in FIG. 11) as more clearly shown in FIGS. 12A and 12B, portions of one or more of the layers 11 to 14 applied via the coating steps 112 to 116 may be removed to form the basis of individual photovoltaic modules. The number of layer 11 to 14 removed may depend on the conductivity of the layers 11 to 14. Typically, portions of the second charge selective layer 14 in areas denoted by 202, 204 in FIG. 12B are removed. In some instances, if the conductivity of the charge transport layer (also known as the photo active layer 13) is too high, portions of layers 11 to 14 are removed as more clearly illustrated in FIGS. 12A and 12B. FIG. 12A illustrates a plan view of the substrate 10 carrying each of the layers 11 to 14 after the coating steps 112 to 116 are complete. FIG. 12B illustrates the substrate 10 after the relevant portions of each layer 11 to 14 are removed via any suitable method including delamination and/or scratching so as to create spaces 202, 204 between individual photovoltaic modules.

[0216] During a fifth step 120, the second conducting electrode layer 15 is applied via a screen printing process, in which a layer of conductive material is applied to a mesh in a screen, a stencil is created by blocking off parts of the screen in the negative image of the photovoltaic module design to be printed. In one embodiment, the photovoltaic modules are printed with linkable gaps in the inter-module rails and between the modules and bus bars. Thickness of screen printed layer can be controlled by a few parameters including mesh size, thickness of the screen, solid contents in the printed paste, squeeze angle and squeeze pressure. The first two parameters are major control parameters. Typically, the thickness of the second conducting electrode layer 15 may be around 1 um to 10 um. The second conductive electrode layer 15 completes the formation of each photovoltaic module 130, the associated inter-module rails 132 and bus bars 134, 136.

[0217] During a sixth step 122 (also not shown in FIG. 11), the substrate 10 is cut to the desired length. Whilst this cutting step 122 can be also carried out after some interconnections are made.

[0218] During the final seventh step 124, desirable interconnections on the inter-module rails to connect adjacent photovoltaic modules, and interconnections between the photovoltaic modules and the bus bars are carried out using a distally controlled dispenser. In some embodiments, the interconnections may be formed via conductive tape. In alternative embodiments, existing electric connections may be broken by any suitable process, for example, via etching and/or perforation process. Once the interconnections/disconnections are complete, the printed solar film is encapsulated via a lamination process to protect the substrate 10 and formed layers 11 to 15. The method 110 advantageously allows the design of each photovoltaic apparatus to be customised during step 124 as part of the manufacturing process, and prior to final encapsulation of the solar film.

[0219] By providing the selectively configurable junctions which are incorporated into the photovoltaic apparatus design, one or more template or generic photovoltaic apparatus designs can be utilised during production (e.g. via steps 112 to 122 above). The customised interconnections for each photovoltaic apparatus can be then carried out in step 124 before laminating the printed solar film for protection. For example, the dispenser at step 124 can be programed to create the desired interconnections at the selected junctions. Accordingly, embodiments of the present invention advantageously allow rapid production of high volume custom designed photovoltaic apparatus to suit different application requirements, without the need for further re-configuration after lamination. That is, embodiments of the invention allow different custom designed photovoltaic apparatus to be mass produced on demand in a flexible manner at relatively low costs.

[0220] Where the terms comprise, comprises, comprised or comprising are used in this specification (including the claims) they are to be interpreted as specifying the presence of the stated features, integers, steps or components, but not precluding the presence of one or more other features, integers, steps or components, or group thereof.

[0221] While the invention has been described in conjunction with a limited number of embodiments, it will be appreciated by those skilled in the art that many alternatives, modifications and variations in light of the foregoing description are possible. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variations as may fall within the spirit and scope of the invention as disclosed.

[0222] The present application may be used as a basis or priority in respect of one or more future applications and the claims of any such future application may be directed to any one feature or combination of features that are described in the present application. Any such future application may include one or more of the following claims, which are given by way of example and are non-limiting in regard to what may be claimed in any future application.