A TWO-TERMINAL DEVICE
20230135300 · 2023-05-04
Inventors
- Trevor MCARDLE (Sunderland, GB)
- Alexander John Topping (Sunderland, GB)
- Nicholas KASCH (Sunderland, GB)
Cpc classification
H01L31/047
ELECTRICITY
Y02E60/10
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
H01L31/0443
ELECTRICITY
Y02E10/50
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
H01L31/0504
ELECTRICITY
International classification
H01L31/0443
ELECTRICITY
H01L31/047
ELECTRICITY
Abstract
There is provided a two-terminal device, including a substrate comprising a first cell having a first characteristic resistance, and a second cell, spaced apart from the first cell along the web direction of the substrate, having a second characteristic resistance; a first terminal and a second terminal, each terminal being formed towards or at opposing edges of the substrate across the transverse direction, and each terminal being in electrical communication with the first cell and the second cell; and a connecting portion, between the first cell and the second cell, the connecting portion having a third characteristic resistance; wherein the third characteristic resistance is greater than or equal to at least one of the first characteristic resistance and the second characteristic resistance. There is also provided a method of forming such a two-terminal device).
Claims
1. A two-terminal device, including a substrate comprising: a first cell having a first characteristic resistance, and a second cell, spaced apart from the first cell along a web direction of the substrate, having a second characteristic resistance; a first terminal and a second terminal, each terminal being formed towards or at opposing edges of the substrate across a transverse direction, and each terminal being in electrical communication with the first cell and the second cell; a connecting portion, between the first cell and the second cell, the connecting portion providing electrical connectivity between the first cell and the second cell, and having a third characteristic resistance; wherein the third characteristic resistance is greater than both the first characteristic resistance and the second characteristic resistance, such that an electrical charge from the first or second cell is extractable at the first terminal or the second terminal in preference to transferring between the first cell and the second cell across the connecting portion.
2. (canceled)
3. A two-terminal device according to claim 1, wherein the third characteristic resistance is at least two times greater than at least one of the first characteristic resistance and the second characteristic resistance.
4. A two-terminal device according to claim 1, wherein the connecting portion comprises at least one resistive element, wherein the at least one resistive element comprises at least one of a peak of the substrate and/or a rutted portion of the substrate.
5. (canceled)
6. A two-terminal device according to claim 4, wherein the at least one resistive element comprises a channel in the substrate, wherein the channel is formed as a depression, an indentation, or an etch in the substrate.
7. (canceled)
8. A two-terminal device according to claim 6, wherein the first cell comprises a first series of grooves and/or the second cell comprises a second series of grooves, wherein the channel transects a portion of the first series of grooves and/or a portion of the second series of grooves, wherein the portion where the channel transects the first series of grooves and/or the second series of grooves is located towards an end of each groove.
9. (canceled)
10. A two-terminal device according to claim 4, wherein the at least one resistive element comprises a plurality of channels in the substrate.
11. (canceled)
12. A two-terminal device according to claim 10, wherein the first cell comprises a first series of grooves and/or the second cell comprises a second series of grooves, and wherein each channel of the plurality of channels transects a portion of the first series of grooves and/or a portion of the second series of grooves, wherein the portion where the channels transects the first series of grooves and/or the second series of grooves is located towards an end of each groove.
13. (canceled)
14. A two-terminal device according to claim 10, wherein the plurality of channels comprises a first channel, having a first channel characteristic resistance, a second channel, having a second channel characteristic resistance, and a third channel, having a third characteristic resistance, wherein the first channel characteristic resistance, the second channel characteristic resistance, and the third channel characteristic resistance provide substantially all of the third characteristic resistance.
15. (canceled)
16. A two-terminal device according to claim 6, wherein the channel or each channel of the plurality of channels is substantially Z-shaped having a predetermined angle.
17. (canceled)
18. A two-terminal device according to claim 10, wherein the first cell comprises a first series of grooves and the second cell comprises a second series of grooves, the substrate further comprising: a first transection channel that transects each channel of the plurality of channels at a distal end of each channel and transects a portion of the first series of grooves; and a second transection channel that transects each channel of the plurality of channels at a proximal end of each channel and transects a portion of the second series of grooves.
19. A two-terminal device according to claim 18, wherein the first transection channel and/or the second transection channel transect the portion of the first series of grooves and/or the portion of the second series of grooves towards an end of each groove.
20. (canceled)
21. A two-terminal device according to claim 18, wherein each channel of the plurality of channels, the first transection channel and the second transection channel form a substantial Z-shape having a predetermined angle.
22. (canceled)
23. A two-terminal device according to claim 6, wherein the channel has an aspect ratio of at least 1:1.6.
24. A method of forming a two-terminal device, comprising: providing a substrate; forming a first cell within the substrate, the first cell having a first characteristic resistance; forming a second cell within the substrate, spaced apart from the first cell along a web direction of the substrate, the second cell having a second characteristic resistance; forming a first terminal and a second terminal, each terminal being formed towards or at opposing edges of the substrate across the web direction, and at least one of the first terminal and/or the second terminal being formed in electrical connection with the first cell and the second cell; forming a connecting portion, between the first cell and the second cell, the connecting portion providing electrical connectivity between the first cell and the second cell, and having a third characteristic resistance; wherein the third characteristic resistance is greater than both the first characteristic resistance and the second characteristic resistance, such that an electrical charge from the first or second cell is extracted at the first terminal or the second terminal in preference to transferring from the first cell to the second cell across the connecting portion.
25. A method according to claim 24, wherein: the step of forming a first cell comprises forming a first series of grooves within the substrate; the step of forming a second cell comprises forming a second series of grooves within the substrate; and the step of forming a connecting portion comprises forming at least one channel within the connecting portion; the method further comprising: coating a first face of at least one of each groove of the first series of grooves, each groove of the second series of grooves, and/or the at least one channel with a first material; coating a second face of at least one of each groove of the first series of grooves, each groove of the second series of grooves, and/or the at least one channel with a second material; and at least partially filling each groove of the first series of grooves, each groove of the second series of grooves and the at least one channel with a third material; wherein the third material is a perovskite structured material.
26. A method according to claim 24, wherein: the step of forming a first cell comprises forming a first series of grooves in the substrate; the step of forming a second cell comprises forming a second series of grooves; and the method further comprising at least partially filling each groove of the first series of grooves and the second series of grooves with a third material, thereby forming an electrical connection across each groove of the first series of grooves, and an electrical connection across each groove of the second series of grooves; wherein the third material is a perovskite structured material.
27. A two-terminal device according to claim 1, wherein the first cell comprises at least one first groove and/or the second cell comprises at least one second groove, wherein the at least one first groove and/or the at least one second groove is at least partially filled with a third material, wherein the third material comprises one of a capacitor material, a supercapacitor material, a dielectric material, and/or a perovskite structured material.
28. A two-terminal device according to claim 27, wherein the at least one first groove and/or the at least one second groove is coated with a first material on a first face and/or is coated with a second material on a second face.
29. A two-terminal device according to claim 28, wherein the third material contacts the first material coated on the first face and/or the second material coated on the second face.
30. A two-terminal device according to claim 28, wherein the first material comprises at least one of a non-insulating material, a conductor material, a semiconductor material, and/or an electron transfer layer.
31. A two-terminal device according to claim 28, wherein the second material comprises at least one of a non-insulating material, a conductor material, a semiconductor material, and/or a hole transport layer.
32. A two-terminal device according to claim 27, wherein the third material comprises a perovskite structured material, and wherein the perovskite structured material has a general chemical structure of ABX3, where A and B are two different cations of different sizes, and X is an anion that chemically bonds to both A and B.
33. A two-terminal device according to claim 32, wherein the perovskite structured material has an optical bandgap between 1.1 eV and 2.5 eV.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0366] Embodiments of the invention are further described hereinafter with reference to the accompanying drawings, in which:
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DETAILED DESCRIPTION
[0392] Like reference numerals are used to depict like features throughout.
[0393] Various modifications to the detailed designs are described above are envisaged. For example, any number of grooves within any number of series of grooves may be used. Equally, any number of delineation features, such as channels, transection channels or the like may be used. Moreover, any combination of such delineation features may be used.
[0394] It will be clear to a person skilled in the art that features described in relation to any of the embodiments described above can be application interchangeably between the different embodiments. The embodiments described above are examples to illustrate various features of the invention.
[0395] Throughout the description and claims of this specification, the words “comprise” and “contain” and variations of them mean “including but not limited to”, and they are not intended to (and do not) exclude other moieties, additives, components, integers or steps. Through the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.
[0396] Features, integers, characteristics, compounds, chemical moieties or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect embodiment, or example described herein unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract or drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The invention is not restricted to the details of any foregoing embodiments. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.
[0397] The reader's attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.
[0398]
[0399] As shown in
[0400] The two-terminal device 50 of
[0401] Furthermore, as shown in
[0402] Each series of grooves 54a, 54b, 54c provides an electrical connection between a first electrical connection 58 and a second electrical connection 60. The first electrical connection 58 is a positive electrical connection and the second electrical connection 60 is a negative electrical connection in the depicted embodiment. Alternatively, the first electrical connection 58 may be a negative electrical connection and the second electrical connection 60 may be a positive electrical connection. The positive and negative electrical connections 58, 60 may be connected to respective terminals, for example, positive and negative busbars 62, 64 of the two-terminal device 50. In this way, positive electrical charge is carried to the positive busbar 62 and negative electrical charge is carried to the opposing negative busbar 64. The busbars 62, 64 may be connected to another electrical element, such as a capacitor or the like.
[0403] As described herein, the delineation features typically serve to provide an electrical disconnection, or provide electrical isolation, between adjacent series of grooves. However, as described herein, this is oftentimes not possible, and so an electrical short occurs across one or more of the delineation features during manufacture of such devices. In this case, the inventors have surprisingly found that conductive delineations features 56a, 56b, that is delineation features that provide an electrical connection thereacross, can be modelled upon a resistor in parallel with a reverse-biased diode, as shown in
[0404] Furthermore, the inventors have surprisingly found that if the delineation feature 56a, 56b is conductive, said delineation feature 56a, 56b provides charge blocking and substantive electrical isolation between adjacent series of grooves simultaneously. That is, the delineation feature 56a, 56b provides charge blocking in the same orientation that would be used for a bypass diode. In this way, a conductive delineation feature 56a, 56b protects the adjacent series of grooves 54a, 54b, 54c from reverse bias damage, that is, from electrical charge flowing in a direction that is opposite to the flow of electrical charge across each groove within the series of grooves 54a, 54b, 54c. For example, referring to
[0405]
[0406] The two-terminal device 100 may be an optoelectronic device, such as a solar photovoltaic cell. Such a two-terminal device 100 includes a mixture of interdigitated (parallel connected) and cascaded (series connected) grooves 104a-104d. The operating voltage of such a two-terminal device 100 can be controlled by changing the number of series of grooves 104a-104d. Increasing the number of series of grooves 104a-104d increases the operating voltage of the two-terminal device 100. Such a two-terminal device 100 can be operated in parallel or a combination of series and parallel arrangement. It may be an advantage of the two-terminal device 100 that this removes the need for extra process steps to be used to connect the cascaded groove structures in series to achieve the desired output voltage.
[0407] The channel 106 physically separates the cascaded (series connected) grooves 104a-104d. The channel 106 enables the cascaded grooves 104a-104d to be connected in parallel via electrical connection to first and second terminals 112, 114. In this way, it is possible to extract the desired electric charge generated at the voltage designed by the number of cascaded groove structures 104a-104d.
[0408] The channel 106, also referred to as the delineation or structural delineation feature, first crosses the first series of grooves 104a towards one end of the substrate 102 and then crosses a spacer 108 between the first series of grooves 104a and the second series of grooves 104b, and subsequently crosses the second series of grooves 104b towards the opposite edge of the substrate 102. Since many of these channels 106 are used, each series of grooves, 104a, 104b for example, are crossed toward each edge by elements of two successive individual channels 106, as shown in
[0409] Together, the spacers 108 and channels 106 divide the substrate 102 into a first area 110a and a second area 110b. The first area 110a carries a positive charge and the second area 110b carries a negative charge. The first area 110a terminates at a first or positive terminal 112 at one edge of the substrate 102, and the second area 110b terminates at a second or negative terminal 114 at the other, opposite, edge of the substrate 102, referring to the transverse direction TD. The first area 110a provides an electrical connection of the first groove of each series of grooves 104a-104d to the first terminal 112. The second area 110b provides an electrical connection of the last groove of each series of grooves 104a-104d to the second terminal 114. Thus, a two-terminal device 100 having a first terminal 112 and a second terminal 114 is formed.
[0410]
[0411] The two-terminal device 200 may be an optoelectronic device, such as a solar photovoltaic cell. Such a two-terminal device 200 includes a mixture of interdigitated (parallel connected) and cascaded (series connected) grooves 204a-204d. The operating voltage of such a two-terminal device 200 can be controlled by changing the number of series of grooves 204a-204d. Increasing the number of series of grooves 204a-204d increases the operating voltage of the two-terminal device 200. Such a two-terminal device 200 can be operated in parallel or a combination of series and parallel arrangement. It may be an advantage of the two-terminal device 200 that this removes the need for extra process steps to be used to connect the cascaded groove structures in series to achieve the desired output voltage.
[0412] Each channel of the plurality of channels 206a-206c physically separates the cascaded (series connected) grooves 204a-204d. Each of the plurality of channels 206a-206c enables the cascaded (series connected) grooves 204a-204d to be electrically connected in parallel to first and second terminals 212, 214. In this way, it is possible to extract the desired electric charge generated at the voltage designed by the number of cascaded groove structures 204a-204d.
[0413] The first channel 206a, also referred to as the first delineation or structural delineation feature, first crosses the first series of grooves 204a towards one end of the substrate 202 and then crosses a space 208 between the first series of grooves 204a and the second series of grooves 204b, and subsequently crosses the second series of grooves 204b towards the opposite edge of the substrate 202. Since many of these channels are used, each series of grooves, 204a, 204b for example, are crossed toward each edge by elements of two successive individual channels, as shown in
[0414] The second channel 206b, like the first channel 206a, first crosses the first series of grooves 204a towards one end of the substrate 202 and then crosses a spacer 208 between the first series of grooves 204a and the second series of grooves 204b, and subsequently crosses the second series of grooves 204b towards the opposite edge of the substrate 202. The third channel 206c crosses the first series of grooves 204a, the spacer 208, and the second series of grooves 204b, in the same manner as the first channel 206a and the second channel 206b.
[0415] It may be advantageous to use a plurality of channels 206a-206c to mitigate the likelihood of an electrical short forming across the interface between the first series of grooves 204a and the second series of grooves 204b, that is, across the plurality of channels 206a-206c. Thus, a plurality of channels 206a-206c ensure a more efficient and reliable two-terminal device 200.
[0416] Together, the spacers 208 and channels 206 divide the substrate 202 into a first area 210a and a second area 210b. The first area 210a carries a positive charge and the second area 210b carries a negative charge. The first area 210a terminates at a first or positive terminal 212 at one edge of the substrate 202, and the second area 210b terminates at a second or negative terminal 214 at the other, opposite, edge of the substrate 202, referring to the transverse direction TD. The first area 210a provides an electrical connection of the first groove of each series of grooves 204a-204d to the first terminal 212. The second area 210b provides an electrical connection of the last groove of each series of grooves 204a-204d to the second terminal 214. Thus, a two-terminal device 200 having a first terminal 212 and a second terminal 214 is formed.
[0417]
[0418] The two-terminal device 300 may be an optoelectronic device, such as a solar photovoltaic cell. Such a two-terminal device 300 includes a mixture of interdigitated (parallel connected) and cascaded (series connected) grooves 304a-304d. The operating voltage of such a two-terminal device 300 can be controlled by changing the number of series of grooves 304a-304d. Increasing the number of series of grooves 304a-304d increases the operating voltage of the two-terminal device 300. Such a two-terminal device 300 can be operated in parallel or a combination of series and parallel arrangement. It may be an advantage of the two-terminal device 300 that this removes the need for extra process steps to be used to connect the cascaded groove structures in series to achieve the desired output voltage.
[0419] The delineation features (306a, 306b, 306c, 316, 318) physically separates the cascaded (series connected) grooves 304a-304d. The delineation features enables the cascaded (series connected) grooves 304a-304d to be connected in parallel via electrical connection to first and second terminals 312, 314, In this way, it is possible to extract the desired electric charge generated at the voltage designed by the number of cascaded groove structures 304a-304d.
[0420] The delineation feature comprises a plurality of channels, specifically a first channel 306a, a second channel 306b and a third channel 306c. Each channel 306a-306c is connected at their distal ends to a first transection channel 316, and connected at their proximal ends to a second transection channel 318. The first and second transection channels 316, 318 form part of the delineation feature and may be substantially channel-like, or may be further channels. The first and second transection channels 316, 318 generally connect to each channel 306a-306c perpendicularly at their respective ends. The first transection channel 316 first crosses the first series of grooves 304a towards one end of the substrate 302 and then crosses a spacer 308 between the first series of grooves 304a and the second series of grooves 304b, and subsequently crosses the second series of grooves 304b towards the opposite edge of the substrate 302. Since many of these delineation features are used, each series of grooves, 304a, 304b for example, are crossed toward each edge by elements of two successive transection channels 316, 318, as shown in
[0421] It may be advantageous to use a plurality of channels 306a-306c between the series of grooves to mitigate the likelihood of an electrical short forming across the interface between the first series of grooves 304a and the second series of grooves 304b, that is, across the delineation feature. Furthermore, the described arrangement, specifically of transection channels 316, 318 at each end of each channel 306a-306c, may provide for an easier manufacture of such efficient and reliable substrates.
[0422] Together, the spacers 308 and the plurality of channels 306a-306c divide the substrate 302 into a first area 310a and a second area 310b. The first area 310a carries a positive charge and the second area 310b carries a negative charge. The first area 310a terminates at a first or positive terminal 312 at one edge of the substrate 302, and the second area 310b terminates at a second or negative terminal 314 at the other, opposite, edge of the substrate 302, referring to the transverse direction TD. The first area 310a provides an electrical connection of the first groove of each series of grooves 304a-304d to the first terminal 312. The second area 310b provides an electrical connection of the last groove of each series of grooves 304a-304d to the second terminal 314. Thus, a two-terminal device 300 having a first terminal 312 and a second terminal 314 is formed.
[0423]
[0424] The two-terminal device 400 may be an optoelectronic device, such as a solar photovoltaic cell. Such a two-terminal device 400 includes a mixture of interdigitated (parallel connected) and cascaded (series connected) grooves 404a-404c. The operating voltage of such a two-terminal device 400 can be controlled by changing the number of series of grooves 404a-404c. Increasing the number of series of grooves 404a-404c increases the operating voltage of the two-terminal device 400. Such a two-terminal device 400 can be operated in parallel or a combination of series and parallel arrangement. It may be an advantage of the two-terminal device 400 that this removes the need for extra process steps to be used to connect the cascaded groove structures in series to achieve the desired output voltage.
[0425] The channel 406 physically separates the cascaded (series connected) grooves 404a-404c. The channel 406 enables the cascaded grooves 404a-404c to be connected in parallel via electrical connection to first and second terminals 412, 414. In this way, it is possible to extract the desired electric charge generated at the voltage designed by the number of cascaded groove structures 404a-404c.
[0426] The channel 406, also referred to as a delineation feature or structural delineation feature, comprises first region, extending along the machine direction MD, a second region extending along the machine direction MD and substantially parallel to the first region, and a third region therebetween extending along the transverse direction TD and connecting the first region to the second region. The channel 406 first crosses the first series of grooves 404a towards one end of the substrate 402 and then crosses a spacer 408 between the first series of grooves 404a and the second series of grooves 404b, and subsequently crosses the second series of grooves 404b towards the opposite edge of the substrate 402. Since many of these channels 406 are used, each series of grooves, 404a, 404b for example, are crossed toward each edge by elements of two successive channels 406, as shown in
[0427] Moreover, the channel 406 are substantially Z-shaped in the depicted embodiment. As shown in
[0428] It may be desirable to use a Z-shaped channel 406 as this can be advantageous during the manufacture of such substrates. As described further below, such substrates are coated using off-axis directional coating methods. Thus, by providing an angle between the various regions of the channel 406, the shadowing effect is increased, thereby providing regions of the channel 406 that are not coated with material. In this way, the likelihood of a short circuit across the channel 406 is mitigated, as described further below.
[0429] Together, the spacers 408 and the channels 406 divide the substrate 402 into a first area 410a and a second area 410b. The first area 410a carries a positive charge and the second area 410b carries a negative charge. The first area 410a terminates at a first or positive terminal 412 at one edge of the substrate 402, and the second area 410b terminates at a second or negative terminal 414 at the other, opposite, edge of the substrate 402, referring to the transverse direction TD. The first area 410a provides an electrical connection of the first groove of each series of grooves 404a-404c to the first terminal 412. The second area 410b provides an electrical connection of the last groove of each series of grooves 404a-404c to the second terminal 414. Thus, a two-terminal device 400 having a first terminal 412 and a second terminal 414 is formed.
[0430]
[0431] The two-terminal device 500 of
[0432] It may be desirable to use a Z-shaped channel 506 as this can be advantageous during the manufacture of such substrates. As described further below, such substrates are coated using off-axis directional coating methods. Thus, by providing an angle between the various regions of the channel 506, the shadowing effect is increased, thereby providing regions of the channel 506 that are not coated with material. In this way, the likelihood of a short circuit across the channel 506 is mitigated, as described further below. Moreover, the Z-shaped channel 506 may be preferred as it allows for a more efficient use of space between the series of grooves 504a-504d.
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[0436] The groove 604, specifically the groove base 650, tends towards the channel 606, specifically the channel base 654, in a transection region 652. The transection region 652 has a transection region base 656 that is substantially arcuate in the example shown. That is, the transection region base 656 has a variable depth as it tends from the groove base 650 to the channel base 654. The variable depth is non-linear in the depicted example.
[0437]
[0438] The groove 704, specifically the groove base 750, tends towards the channel 706, specifically the channel base 754, in a transection region 752. The transection region 752 has a transection region base 756 that is substantially linear, or straight, in the example shown. That is, the transection region base 756 has a variable depth as it tends from the groove base 750 to the channel base 754. The variable depth is linear in the depicted example.
[0439] As shown in
[0440]
[0441] The respective steps 810, 820, 830, 840 may be carried out sequentially, that is in an order. For example, the steps 810, 820, 830, 840 may be carried out in the order as described in
[0442] The step of forming 840 the channel further includes forming the channel such that the channel transects a portion of the first series of grooves and the second series of grooves towards a proximal end of each groove. Furthermore, the step of forming 840 the channel includes forming a depth of each groove that tends towards the depth of the channel at the proximal end of each groove.
[0443] In some examples, one or more of the steps of forming 820 a first series of grooves, forming 830 a second series of grooves and forming 840 a channel therebetween includes an embossing process, as described in relation to
[0444]
[0445] As the protrusions 908 engage the coated web of flexible material (902, 904), the UV-curable coating 904 is at least partially UV-cured 940 during the engagement step 930. The protrusions 908 are then removed 950 from the coated web of flexible material (902, 904). As the protrusions 908 are removed 950, the coated web of flexible material (902, 904) is caused to be drawn towards the protrusions 908 of the cylindrical stamping roll 906 as they are removed 950, due to the partial UV-curing of the UV-curable coating 904. However, since the UV-curable coating 904 is only partially UV-cured, that is not fully cured, the coated web of flexible material (902, 904) then relaxes as the protrusions 908 of the cylindrical stamping roll 906 are fully removed. In this way, the transection region between the first series of grooves or the second series of grooves and the channel is first caused to be drawn upwardly, towards the cylindrical stamping roll 906, and then relaxes, such that the transection region is formed in a manner such that the depth of the grooves tends towards the depth of the channel, as described above.
[0446] The cylindrical stamping roll 906 is continually rolled 960 across the machine direction MD of the coated web of flexible material (902, 904). Thus, the process is repeated along the machine direction MD. It may also be desirable to cut the formed substrate at various intervals along the machine direction MD. In such cases, the method 900 may optionally include the step of cutting the master substrate into a plurality of substrates.
[0447]
[0448] The coating steps 1020, 1040 may comprise an off-axis directional coating as best shown in
[0449]
[0450] In comparison, referring to
[0451] The method 1000 further includes the step of at least partially filling 1060 the channel 1010 with a third material 1016. The third material 1016 may be different to the first material 1012 and the second material 1014. In some examples, the step of at least partially filling 1060 the channel 1010 may comprise a printing process. In addition to the channel 1010 being filled with a third material 1016, the first series of grooves 1006, the second series of grooves 1008, or both the first and second series of grooves 1006, 1008 may be at least partially filled with the same third material 1016, as shown in
[0452] The first material 1012, the second material 1014 and the third material 1016 vary depending on the intended use of the two-terminal device that is to be formed. For example, in some cases it may be desirable to produce a solar photovoltaic device that can supply electricity to a device. In this example, the first material 1012 may be a non-insulating material, such as a conductor or a semiconductor, the second material 1014 may be a non-insulating material, such as a conductor or a semiconductor, and the third material 1016 may be a perovskite structured material. As would be recognised by the person skilled in the art, the two-terminal device can be produced with the appropriate coatings that are suitable for the intended final use of the two-terminal device to be produced.
[0453]
[0454] The first series of grooves 1104 include a first face 1104a, a second, opposing, face 1104b, and a cavity 1104c therebetween. The second series of grooves 1106 include a first face 1106a, a second, opposing, face 1106b, and a cavity 1106c therebetween. The channel 1108 includes a first face 1108a, a second, opposing, face 1108b, and a cavity 1108c therebetween. The first faces 1104a, 1106a, 1108a are coated with a first material 1110. The second face 1104b, 1106b, 1108b are coated with a second material 1112. Additionally, a third material 1114 is provided within the cavities 1104c, 1106c, 1108c. As shown in
[0455] As can be seen in
[0456]
[0457] The first faces 1204a, 1206a, 1208a, 1209a are coated with a first material 1210. The second faces 1204b, 1206b, 1208b, 1209b are coated with a second material 1212. Additionally, a third material 1214 is provided within the cavities 1204c, 1206c, 1208c, 1209c. The cavities 1204c, 1206c of the first and second series of grooves 1204, 1206 are filled to the extent that the first material 1210 and the second material 1212 on opposing faces (1204a, 1204b and 1206a, 1206b) are in contact with the third material 1214. This forms an electrical pathway across the first series of grooves 1204 of the first cell, and between the second series of grooves 1206 of the second cell.
[0458] The cavity 1208c of the first channel 1208 is partially filled with the third material 1214 such that the third material 1214 in the cavity 1208c does not contact the first material 1210 on the first face 1208a and the second material 1212 on the second face 1208b. No electrical pathway is provided between the third material 1214 and the first material 1210 on the first face 1208a. No electrical pathway is provided between the third material 1214 and the second material 1212 on the second face 1208b. The cavity 1209c of the second channel 1209 is partially filled with the third material 1214 such that the third material 1214 in the cavity 1209c does not contact the first material 1210 on the first face 1209a and the second material 1212 on the second face 1209b. No electrical pathway is provided between the third material 1214 and the first material 1210 on the first face 1209a. No electrical pathway is provided between the third material 1214 and the second material 1212 on the second face 1209b. The first and second channels 1208, 1209 ensure there is an electrical resistance from one side of the connecting portion to the other.
[0459] In use, the combined resistance across the first and second channels 1208, 1209, that is the resistance across the connecting portion, is greater than the resistance across the first cell. The combined resistance across the first and second channels 1208, 1209 is greater than the resistance across the second cell. More specifically, the first cell has a first characteristic resistance. The second cell has a second characteristic resistance. The combined resistance across the first and second channels 1208, 1209 is a third characteristic resistance that is greater than the first characteristic resistance across the first cell. The third characteristic resistance is greater than the second characteristic resistance across the second cell. By having a combined resistance across the first and second channels 1208, 1209 that is greater than the resistance across the first cell and the second cell, charge is extracted from the first and second terminals, rather than being transferred across between the first cell and the second cell, across the connecting portion. In this particular example, the resistance value of the first characteristic resistance and the value of the second characteristic resistance are the same. It is envisaged that in some examples, the third characteristic resistance across the connecting portion is equal to at least one of the first characteristic resistance and the second characteristic resistance. It is envisaged that more than two channels 1208, 1209 may be provided between the first cell and the second cell. By providing multiple channels between the first cell and the second cell, the combined resistance is increased with the number of channels. The space between the channels may be increased to further increase the combined resistance across the connecting portion. In this particular example, the combined resistance across the connecting portion is five times the resistance across the first cell. In this particular example, the resistance across the connecting portion is also five times the resistance across the second cell. The resistance across the first cell and across the second cell are the same in this particular example.
[0460]
[0461] In use, the resistance across the connecting portion is greater than the resistance across the first cell 1304. The resistance across the connecting portion is also greater than the resistance across the second cell 1306. More specifically, the first cell has a first characteristic resistance. The second cell has a second characteristic resistance. The resistance across the connecting portion is a third characteristic resistance that is greater than the first characteristic resistance across the first cell 1304. The third characteristic resistance is also greater than the second characteristic resistance across the second cell 1306. By having an arrangement where the resistance across the connecting portion is greater than the first characteristic resistance across the first cell 1304 and greater than the second characteristic resistance across the second cell 1306, charge is extracted from the first and second terminals, rather than being transferred across the first and second terminals. In this particular example, the third characteristic resistance is three times the first characteristic resistance across the first cell 1304. The third characteristic resistance is there times the second characteristic resistance across the second cell 1306. In some examples, the connecting portion is additionally provided with a resistive element (not shown) that increases the resistance across the connecting portion.
[0462]
[0463] The first material 1410 coating the first face 1406a of the groove 1404 proximal the connecting portion 1408 partially coats the connecting portion 1408. In this way, the connecting portion 1408 provided between the first cell 1404 and the second cell 1406 is partially coated with a second material 1412 on the end of the connecting portion 1408 proximal the first cell 1404. The connecting portion 1408 provided between the first cell 1404 and the second cell 1406 is partially coated with a first material 1410 on the end of the connecting portion 1408 proximal the second cell 1406. The connecting portion 1408 is therefore provided between the first cell 1404 and the second cell 1406, partially coated with a second material 1412 on a first end proximal the first cell 1404, and is partially coated with a first material 1410 on a second end proximal the second cell 1406. The first material 1410 and the second material 1412 partially coating the connecting portion 1408 are electrically separated from one another. The connecting portion 1408 ensures an electrical resistance from one side to the other.
[0464] In use, the resistance across the connecting portion 1408 is greater than the resistance across the first cell 1404. The resistance across the connecting portion 1408 is greater than the resistance across the second cell 1406. The first cell 1404 has a first characteristic resistance. The second cell 1406 has a second characteristic resistance. The resistance across the connecting portion 1408 is a third characteristic resistance that is greater than the first characteristic resistance across the first cell 1404. The third characteristic resistance is greater than the second characteristic resistance across the second cell 1406. The arrangement of having a greater resistance across the connecting portion 1408 between the first cell 1404 and the second cell 1406 allows charge from the first or second cell to be extracted from the first and second terminals, rather than being transferred between the first cell 1404 and the second cell 1406, across the connecting portion 1408.
[0465]
[0466] The first faces 1504a, 1506a, 1508a are coated with a first material 1510. The second faces 1504b, 1506b, 1508b are coated with a second material 1512. Additionally, a third material 1514 is provided within the cavities 1504c, 1506c, 1508c. The cavities 1504c, 1506c of the first cell 1504 and second cell 1506 respectively are filled to the extent that the first material 1510 and the second material 1512 on opposing faces (1504a, 1504b and 1506a, 1506b) are in contact with the third material 1514. This forms an electrical pathway across the first cell 1504, and across the second cell 1506.
[0467] Unlike the two-terminal device shown in
[0468] In use, the resistance across the connecting portion is greater than the resistance across the first cell 1504. The resistance across the connecting portion is greater than the resistance across the second cell 1506. The first cell 1504 has a first characteristic resistance. The second cell 1506 has a second characteristic resistance. The resistance across the connecting portion is a third characteristic resistance that is greater than the first characteristic resistance across the first cell 1504. The third characteristic resistance is greater than the second characteristic resistance across the second cell 1506. This arrangement allows charge from the first or second cell to be extracted from the first and second terminals, rather than being transferred between the first cell 1504 and the second cell 1506, across the connecting portion 1508.
[0469]
[0470] The first faces 1604a, 1606a, 1608a are coated with a first material 1610. The second faces 1604b, 1606b, 1608b are coated with a second material 1612. Additionally, a third material 1614 is provided within the cavities 1604c, 1606c, 1608c. The cavities 1604c, 1606c of the first cell 1604 and the second cell 1606 respectively, are filled to the extent that the first material 1610 and the second material 1612 on opposing faces (1604a, 1604b and 1606a, 1606b) are in contact with the third material 1614. This forms an electrical pathway across the grooves of the first cell 1604, and between the grooves of the second cell 1606.
[0471] In this particular example, each of the grooves of the bottom rutted portion, forming the cavity 1608c, is partially filled, for example coated, with the third material 1614. In this way, the third material 1614 forms a coating, or a conformed coating or a film, of the third material 1614 within the undulations of the channel 1608. Thus, the third material 1614 is in contact with the first material 1610 on the first face 1608a. The third material 1614 also contacts the second material 1612 on the second face 1608b. An electrical pathway is provided between the third material 1614 and the first material 1610 on the first face 1608a. An electrical pathway is provided between the third material 1614 and the second material 1612 on the second face 1608b. The connecting portion provides an electrical connection from one side to the other. That is, the connecting portion provides an electrical connection from one side of the connecting portion proximal the first cell 1604, to the other side of the connecting portion proximal the second cell 1606.
[0472] In use, the resistance across the connecting portion is greater than the resistance across the first cell 1604. The resistance across the connecting portion is also greater than the resistance across the second cell 1606. The first cell 1604 has a first characteristic resistance. The second cell 1606 has a second characteristic resistance. The resistance across the connecting portion has a third characteristic resistance that is greater than the first characteristic resistance across the first cell 1604. The third characteristic resistance across the connecting portion is greater than the second characteristic resistance across the second cell 1606. By having a resistance across the connecting portion that is greater than the resistance across the first cell 1604 and the second cell 1606, charge from the first or second cell is extracted from the first and second terminals, rather than being transferred across between the first cell 1604 and the second cell 1606.
[0473]
[0474] A connecting portion, including a peak 1708 of the substrate 1702 is provided between the first cell 1704 and the second cell 1706. The peak 1708 is provided with a first face 1708a and a second, opposing, face 1708b. In this example, the peak 1708 is directed upwards, in a direction opposite to the direction of the grooves of the first cell 1704 and the second cell 1706. The first face 1708a of the peak 1708 is provided on a side proximal the first cell 1704. The second face 1708b of the peak 1708 is provided on a side proximal the second cell 1706. The peak 1708 has a height that is greater than the depth of the grooves of each of the first cell 1704 and the second cell 1706. In this particular example, the peak 1708 is formed from a block material. having a first material disposed on the first face 1708a and a second material disposed on the second face 1708b. This first and second materials disposed thereon may be the same as the first and second material 1710, 1712 disposed on the faces 1704a, 1704b, 1706a, 1706b of the cells 1704, 1706 as described below. In particular, the first face 1708a may be coated with non-insulating material, such as a conductor. In particular, the second face 1708b may be coated with non-insulating material, such as a conductor. There may be a region between the first face 1708a, 1708b in which no material is provided, such as a gap. This may be provided by removing a portion of the materials provided on the first face 1708a and the second face 1708b. Alternatively, such a portion may be masked during manufacturing. Further, in other embodiments, the upper portion of the block material may be removed after coating the first face 1708a and the second face 1708b, thereby providing an electrical resistance, between the respective faces. In this example, the connecting portion does not have a cavity. The connecting portion includes a peak at an end distal the grooves of the first cell 1704 and the second cell 1706.
[0475] The first faces 1704a, 1706a of the first cell 1704 and second cell 1706 respectively, are coated with a first material 1710. The second faces 1704b, 1706b of the first cell 1704 and second cell 1706 respectively, are coated with a second material 1712. Additionally, a third material 1714 is provided within the cavities 1704c, 1706c of the first cell 1704 and second cell 1706 respectively. The cavities 1704c, 1706c are filled to the extent that the first material 1710 and the second material 1712 on opposing faces (1704a, 1704b and 1706a, 1706b) are in contact with the third material 1714. This forms an electrical pathway across the first cell 1704, and across the second cell 1706.
[0476] In use, the resistance across the connecting portion is greater than the resistance across the first cell 1704. The resistance across the connecting portion is greater than the resistance across the second cell 1706. The first cell 1704 has a first characteristic resistance and the second cell 1706 has a second characteristic resistance. The resistance across the connecting portion is a third characteristic resistance that is greater than the first characteristic resistance across the first cell 1704. The third characteristic resistance is greater than the second characteristic resistance across the second cell 1706. This arrangement allows charge from the first or second cell to be extracted from the first and second terminals, rather than being transferred between the first cell 1704 and the second cell 1706, across the connecting portion.
[0477]
[0478]
[0479]
[0480] It will be appreciated by persons skilled in the art that the above embodiment(s) have been described by way of example only and not in any limitative sense, and that various alterations and modifications are possible without departing from the scope of the invention as defined by the appended claims. Various modifications to the detailed designs as described above are possible, for example, variations may exist in number, shape, size, arrangement, assembly or the like. For example, any number of grooves and any number of series of grooves may be used, any number of channels, or delineation features, may be used. Further, the channel(s) may intersect the grooves at any appropriate angle and may be shaped in any appropriate way. Further, various grooves, channels, connecting portions or the like may be partially filled, filled, completely filled, or coating, as described herein. Mere reference to coating or filling in one embodiment does not preclude the possibility of filling or coating, respectively, the feature of said embodiment.