An artist's impression of spray-coating glass with the polymer to create a solar cell

Spray coating technique lowers cost of solar cells

Solar cells made using a cost-effective spray coating technique have been developed by scientists at the University of Sheffield.

The method could potentially reduce the cost of solar cells significantly meaning the technology could be provided to people in developing countries and perhaps one day be used on glass in buildings or car roofs.

Experts from the University of Sheffield’s Department of Physics and Astronomy collaborating with the University of Cambridge have created a method of spray-coating a photovoltaic active layer by an air based process – similar to spraying regular paint from a can – to develop a cheaper technique which can be mass produced.

Professor David Lidzey from the University of Sheffield said: “Spray coating is currently used to apply paint to cars and in graphic printing.  We have shown that it can also be used to make solar cells using specially designed plastic semiconductors.

“Maybe in the future surfaces on buildings and even car roofs will routinely generate electricity with these materials.

“We found that the performance of our spray coated solar cells is the same as cells made with more traditional research methods, but which are impossible to scale in manufacturing. We now do most of our research using spray coating.

“The goal is to reduce the amount of energy and money required to make a solar cell. This means that we need solar cell materials that have low embodied energy, but we also need manufacturing processes that are efficient, reliable and consume less energy.”

Most solar cells are manufactured using energy intensive tools and materials like silicon that contain large amounts of embodied energy whereas plastic requires much less energy to make.

By spray-coating a plastic layer in air the team hope the overall energy used to make a solar cell can be significantly reduced and while at present devices are coated onto flat surfaces but there is nothing to stop the technique being used for curved surfaces.

The main restrictions of the technique are that at present such surfaces need to be very smooth and plastics are not currently as efficient at generating electricity as cells made from silicon.

The vast majority of solar panels found in the UK are made from silicon and are expected to last more than 25 years and it is unlikely that plastic cells will ever be this stable, but if the energy cost of plastic cells can be lowered enough they will become more cost-effective than silicon over their life cycle.

Professor Lidzey added: “Increasing the energy conversion efficiency and lifetime of plastic cells are significant issues that many groups are working on. It should also be noted that the cost of silicon solar panels have reduced significantly over the last few years so plastic solar cells will have to catch up with these improvements.”

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