CREATIVE S CIENCE P. O. B OX 557 NEW A LBA NY, IN. 47151
www.fuelless.com .wfuwewllesspower.com
SCIENCE
Creative
& Research
PO BOX 557 New Albany, IN. 47151 USA
Copyright 2002 - 2004 Creative Science & Research
# 401P
C Copyright 2003
Thank you for buying these plans. It will help us in our research efforts and to tell the world about this
suppressed technology.
Included is 3 different ways to make a home made solar cell:
The 1996 japan Patent is by far the best and the most powerful. The japan patent uses a simple process that has
been used for centuries, You simply screen print the negative and positive layers and the contact layers on to a
piece of glass plate, it does not matter how thick the glass is. The layers can be sprayed on with a spray gun
and a air compressor, but it is best to Screen print it. Screen printing each layer will make your solar cells last
longer and they will be more efficient
If you do not know what screen printing is, you can learn about this very simple process from the Library.
Also lots of info and supplies can be purchased at your local hobby store or art supply store. You can also buy
supply's such as screens and such at a local Screen printing shop. or they can screen print it for you. Screen
printing is very simple and cheap to do for you self right in your own home. It may take a little studying but it
will be worth it. you can print up as many Solar Cells as you want for just pennies. ( Cover your entire roof
with them. You will have more energy than you will ever need. You can then make money selling electricity
back to the electric company which should pay for it self in one to two years. The most expensive part is the
deep cycle marine batteries and your inverters. Many are making a nice income every year from this, just by
selling electricity back to the electric company, ask to see if your electric company has that type of program in
your area. most states I heard do.
The Japan method is new and it is not limited to just a glass surface, you can also apply it right onto
aluminum or copper sheeting. Look at the 1 st page, see the N type layer #2 this is what the Patent says to
Print first. But if you want to print onto a metal surface the metal surface would be #5 then the 1 st print would
be #4 then let it air dry and then bake at 600 degrees for 3 to 5 minutes.
(Each printed layer can be done this way.) Then your 2nd print would be #3, then you let air dry, then bake,
then Print #2 Air dry/bake. Then you must print a Metal grid over #2 then let air dry, (you don't have to bake
the metal print. ) This will be your negative contact, #5 will be your Positive Contact, so what your doing is
just simply reversing the printing layer steps. If you have never seen a solar cell the metal grid is like a metal
door screen but with bigger spacing. You can buy a special metal printing ink or mix it your self as the patent
says. The ink is simply made up of nickel or silver. Nickel is the cheapest and will work just fine.
Please Notice: You can not manufacture and sell the Japan Solar Cells with out there permission If you want
to leam about Screen Printing we sell a VHS Video for only $29.95
Please send $4 for shipping.
The chemicals that are mentioned in the patent are very easy to get. You can buy them in any QTY from any
Chemical supply company look one up in your yellow page phone book. Or check online, search for Chemical
Supply Shops or companies.
Homemade Solar Cells # 401
Page1
Homemade Solar Cells # 401
About Photovoltaics
Photovoltaic (or PV, Solar Cells ) systems convert light energy into electricity. The term "photo" is from the
Greek "phos" which means light. "Volt" is named from Alessandro Volta (1745-1827, He was a pioneer in
the study of electricity. So you could say that" Photo-voltaics is basically light electricity! And is most
commonly known as Solar Cells. Solar cell systems are already a very important part of our lives. The
simplest systems power many of the small calculators and wrist watches we use everyday. PV power is the
cheapest form of electricity for powering these small devices. There are many ways to make solar cells, and
one of the cheapest ways is to screen print them. There are many companies in the USA that are doing this.
Many US Patents have been issued for screen printing solar cells and there are many different chemical inks
that can be used. The Japanese Patent is one of many.
Page 2
Turning Sunlight Into Electricity!
Solar Cells convert light energy into electricity at
the atomic level. It was first discovered in 1839, the
process of producing electric current in a solid
material with the aid of sunlight wasn't truly understood
for more than a hundred years.
Throughout the second half of the 20th century, the
science has been refined and process has been more
fully explained. As a result the cost of these devices
has put them into the mainstream of modem energy
producers. This was caused in part by advances in
technology, where PV conversion efficiencies have
been improved.
Solar Cell Materials
The most important parts of a solar cell are the
semiconductor layers, this is where the electron
current is created. There are a number of different
materials available for making these semiconducting
layers, and each has benefits and drawbacks.
Unfortunately, there is no one ideal material for all
types of cells and applications.
In addition to the semiconducting materials, solar
cells consist of a top metallic grid or other electrical
contact to collect electrons from the semiconductor
and transfer them to the external load, and a back
contact layer to complete the electrical circuit.
Then, on top of the complete cell is typically a glass
cover or other type of transparent encapsulant to
seal the cell and keep weather out, and a antireflective
coating to keep the cell from reflecting the
light back away from the cell. A typical solar cell
consists of a cover glass, a anti-reflective layer, a
front contact to allow the electrons to enter a circuit
and a back contact to allow them to complete the
circuit, and the semiconductor layers where the
electrons begin to complete there voyages!
Homemade Solar Cells # 401
Page 3
12” x 18” 12 vdc
Screen Printed Solar Cells
Scientists in Arizona are using screen-printing, a
technique developed for printing fabrics, paper and
to produce plastic, glass and metal solar cells.
The basic materials of a photovoltaic cell (solar cell)
are inexpensive. The organic manufactured by
Ghassan Jabbour and colleagues at the University of
Arizona in Tucson have about 11/4 of the efficiency
of commercial silicon solar cells, which turn 10-20
per cent of light energy into electricity. But, being
cheap to produce, they can make up the loss in
quantity what they lack in quality. Now the Japan
screen printed solar cells are even better than that!
For more info contact: Matsushita Electric Industrial
co. LTD, Osaka. Japan
In conventional Screen - printing, a taut piece of
screen mesh fabric is stretched over a wood frame,
you can buy the screens already made and the materials
from any screen printing shop or screen printing supply
company in your area or on the internet. Also you might
want to check with your local art store, sometimes they
have full kits etc...
The screen is then masked off using masking tape,
For example: a 5" x 5" square area. the screen outside
of the masking tape is then coated with a block out
liquid or paint, this is so when you apply your semiconducting ink that you mixe, it will go
through just the area that you masked off when you apply a rubber squeegee to it. The
screen can then be placed on any table top and hinges attached to the back of the wood
frame and the table, this will insure the screen can move up and down. Then get a small
wood paint stick and using a small nail, hammer one end to the front side of wood frame.
This will be your kick leg and will help keep your screen in an upward position when
needed. Take a 5" x 5" piece of glass and place it right under the open 5" x 5" area of the
open screen mesh. When the leg is flipped back the screen comes down and you grab
your rubber and wood handled squeegee and with the ink in front of your rubber squeegee
pull toward you applying pressure so ink will go through screen, once you have passed by
the 5" x 5" area then flip the screen back up and reverse squeegee to flood the screen for
the next print.
Homemade Solar Cells # 401
A Screen printing press, the
wood frame is the screen
An example of a Silicon cell
Page 4
The Research group mentioned earlier, Jabbour's group, print very flat,
thin cells, onto glass in a similar way. First they coat the glass with a
transparent electrically conducting material (metal ink) that acts as one of the
solar cell's electrodes. On top of this, they lay down a thin film of a polymer,
which helps to gather current from the photovoltaic material.
Finally they deposit a blend of two organic compounds that convert light into
electricity. One is a carbon-based molecule called a fullerene, it produces
charged particles that carry an electrical current when light shines onto the
molecules. The other is a polymer, it ferries the current to the electrodes on
the top and the bottom of the solar cell.
Under blue light, these screen-printed solar cells have an efficiency of 4.3 per
cent. And the Japanese cells are much greater than that! Many of the flexible
solar cell panels that you see today are screen printed.
Now lets take a look at what The Dupont Company is doing with there solar
cells. Dupont is involved in the development of solar cell metallisation since
the 1970's. Although all PV cell manufacturers use different processes to
make there solar cells, the metallisation of the rear and front sides is in many
cases DONE BY SCREEN PRINTING! Which has shown itself to be one
of the most economic way to produce solar cells.
Recently, Dupont achieved a real breakthrough in the formulation of front-side
contacts for silicon solar cells that has resulted in customers, such as
photowatt, to realize the screen printing efficiency by changing their antireflection
technology from titanium dioxide to silicon nitride. This came at
just the right time for the Photowatt solar cell company, Because they have
been using there own past material for the front side metallisation since it first
started manufacturing solar cells. The development of the metallisation from
Dupont for the back side, (p-side). These pasty inks are either silver pastes
containing Al, or pure Al pastes to secure a good ohmic contact with the pside
of the solar cell. We have told you all this to help you better understand
and leam the screen printing solar cell process and what others are doing.
Homemade Solar Cells # 401
Page 5
The Japan Solar Cell Patent
Note: You can Use an outside Grill to bake the Screen Printed layers. It is a good
idea to make small cells, 8" x 10" or what ever. It is easier to fit into the Grill,
We suggest Baking in side a large roasting pan and then put the roasting pan inside
the preheated grill and shut the lid. It is suggested that you try and make 3 prototype
cells first, Work out all the details, Test them, and then start on a large production of
Solar Cells. It will all get much easier once you have done it. It is also suggested that
you bake them out side. You don't want any fumes in the house, an outside grill is the
best and most readily available oven there is and propane is cheap. I hear you may be
able to make them without a Nitrogen atmosphere if not try special gas companies or
make some yourself, it is supposed to be nonflammable.
Screen Printing: You start with a small 14" x 14" wood frame 2x2". Then a plastic
or clothe screen is stretched over the frame tightly one side at a time, and then stapled
down on all 4 sides, we suggest buying a yellow 200 mesh screen from a screen
printing supplier, Then you put an image of what ever you want to print into the
screen by photo emulsion or by cutting a lacquer or water film with an exacto knife.
( see our Screen Printing Video ) Once you have your image you place the finished
screen onto a flat smooth table top, attach it to a 14" long 2" x 4" with 2 door hinges.
using wood screws, then you attach the 2" x 4" on to the table so it and the screen will
not move. the screen should only go up or down.
you then put your 8" x 10" glass under the screen, register it, then lay the screen
down over the glass and apply your ink and then with a small 12" rubber Squeegee,
You pull the ink over the image and it is pushed thru the screen mesh and thru the
image that you cut and smoothly is printed onto the glass.
SUPPLIERS;
Screen Printing Books and supplies; NDS 1-800-783-3883 Indianapolis, IN.
( See also Art Store's, Hobby Shop's, Arts and Crafts, Screen printing company's.)
They also sell copper sheeting.
Solar Cell Screen Print Chemicals: Search the web, simply type in the chemical
you are looking for and many suppliers will pop up. Example: Cadmium Sulphide
Supplier..... We have checked and you can find all the chemicals and info on them
free on the web.
Also see: www.stanfordmaterials.com/semi.html
Homemade Solar Cells # 401
Page 6
Homemade Solar Cells # 401
The Stanford Materials Company
1. Cadmium Sulphide in powder form = Cds (or if already thick liquid or ink OK.)
2. Cadmium Chloride + Cdcl 2 ( Powder or liquid form )
3. Propylene glycol + pg in liquid form
4. Carbon Powder, if you can not find none make your own wood carbon powder?
5. Cadmium = Cd
6. Tellurium = Te
Page 7
THE COPPER CHLORINE SOLAR CELL: Buy a roll of Thin Copper sheeting, cut
a 1.5" diameter piece out with a pair of cutters, then sand polish the copper on both sides
with some fine grade steel wool. then by using a propane torch heat the copper while
griping it with rubber handled pliers, and let the copper get red hot, until it glows, move
the copper over the flame evenly for about 3 minutes then allow to cool slowly. Then
once it is cooled dip it down in an acid solution of 1/2 water and 1/2 acid, WARNING!
Never pour water into acid always pour acid into water. The acid that you can use is
MURIATIC ACID ( Hydrochloric Acid ) you can buy it at any hardware store, or you
can use a solution of nitric acid. REMEMBER TO WEAR PROTECTIVE
GOGGLES OR OTHER SUITABLE EYE PROTECTION, AND WORK IN A
WELL VENTILATED AREA. DO NOT SMELL THE FUMES OR MAKE
CONTACT WITH YOUR SKIN, WEAR RUBBER GLOVES. THESE ACIDS
CAUSE SEVERE BURNS. KEEP OUT OF THE REACH OF CHILDREN.
NOTICE: WE ARE NOT RESPONSIBLE FOR ANYTHING IN THESE PLANS ,
YOU BUILD AND EXPERIMENT AT YOUR OWN RISK.
Keep it in the acid for only a half a minute or longer, the idea is to keep it dipped in the
acid long enough for the black oxide to come off of the top layer, under that is the photo
sensitive red cuprous oxide. Remember you should only have a dark bright red layer left.
Note: do not leave it in to long it will eat away the red. once you have done that then it's
O.K. to wash off the acid with water, do all of this outside or in your garage, make sure
all of the acid is off. wash no less than 3 minutes, now look at the copper disk on one
side you will have bright copper, this is the positive side, and on the other side you will
have red this the negative side the side you face toward the sun. now mix a small
solution of 95 water and 5 Clorox bleach, now take the red side and look for
scratches if there are any you must paint them with enamel oil base paint, apply paint to
any where on that side where copper is showing through, now glue a plastic lid on to red
side, let it dry them drill a small hole in the top pour in Clorox bleach and water solution
and then place a copper or steel wire through the hole and onto the bottom, wire must be
submerged in the solution, now tape or glue the hole up with the wire in it. now tape
Solar cell out into the sun and using a DC volt meter attach + to the copper back, and - to
the steel wire coming out of hole. you will see the meter move showing a voltage, now
block the sun with your hand and watch the voltage drop.
make many of these for just pennies and put them in series or parallel to increase your
voltage or amperage. These type of cells are only 5 of the japan cells.
I have heard that the Japanese cells are about 95 of the American made silicon cell that
is a very expensive process. Screen printing them is the cheapest way to go and is easy,
once you get the hang of it.
Homemade Solar Cells # 401
Copyright 2003 /all pages
Page 8
Chemicals: needed: 1. Cadmium Sulphide = cds 2. Cadmium Chloride == cdcl 2
( These can be in powder form ) 3. Propylene Glycol = pg this is used to mix the
powders into a pasty but screen printable liquid ink type. 4. Carbon powder, if you can
not find it make some yourself out of burnt wood etc... 5. Cadmium = cd
6. Tellurium = Te
Page 9
Homemade Solar Cells # 401
Copyright 2003 /all pages
Homemade Solar Cells # 401
There are many different ways to construct these home made cells, the above
drawing shows a wire screen mesh that you can buy at any hardware store.
Using wire mesh makes a much more powerful cell, than just using one
strand of wire. before assembly, attach the wire mesh to the red copper side.
use a small weight in the center of the wire mesh and using clear silicon, glue
down the edges, ( make sure you don't get any glue in the area where the
plastic cap is going to sit. ) now let that sit over night, then glue on your clear
plastic cap on to the red copper side of cell.
these also make a great science fair project as well as providing free electricity
to your home. It's going to take some practice if you do any of these projects.
but will be able to make your own FREE Electricity force us out of the closet
so they could shut us down.
+
-
Wire
screen
mesh
(
Hardware
Store
)
Glue Clear
plastic
cap
or
glass
container
Copper Chorline Solar Cell
Negative Wire
Positive Wire
Page 10
Knowledge is Power! Study this Patent well and read all
you can from the free info on the internet as well about
screen printing solar cells and the many different chemicals
that can be used! The Japan Solar Cells are better to make
and will last a long time!
Creative Science & Research: PO BOX 557 New Albany IN, 47151
www.fuelless.com www.fuellesspower.com
Homemade Solar Cells # 401
Page 11
A More Simplified Copper
Solar Cell
Similar to the Copper Chlorine Cells. We have found that if you use Conductive Nickle Paint you will
get far better results. But start out using the screen mesh or the aluminum wire. You can buy Nickle
Paint on the internet. Simply search for “ Nickle Paint suppliers “ on your search engine. You can do
the same for finding thin copper sheeting. There is also a company in Louisville KY, that sells copper
sheeting, see Conner Manufacturing 18th st. Louisville, KY. (502)-587-1387 Or Vendome Copper &
Brass 729 Franklin St. Louisville, KY. 40202 (502) -587-1930
Homemade Solar Cells # 401
Creative Science & Research PO BOX 557 New Albany, IN. 47150
Copyright 2003
Page 12
Warning: You build at your own risk!
The fabrication of a modem solar cell is very complicated and
a delicate process. In most cases, a large silicon ingot is grown
from a small crystal in an extremely clean and sterile environment.
Any dust or particle contamination even down to the
atomic level during the growing process can completely ruin the
ingot. Impurities must typically be kept to one part per billion.
The growing process itself is slow, and the very pure materials
required are extremely costly. Because of this, a single ingot
which is later sliced into thin cells approximately 0.05 centimeters
thick often costs thousands of dollars to produce.
This fact coupled with the general inefficiency (7-14 typically)
of even these modem cells has kept the price of photoelectric
cells too high to be competitive with other sources of power.
Someday, lower cost production techniques together with
higher efficiency will make widespread use of clean, renewable
solar energy possible. Someday solar cells will be a very common
Source of energy, the idea of deriving
electricity directly from
sunlight will continue to excite the
inventor and experimenter.
Page 13
Modern
Homemade Solar Cells # 401
It is well known that if even 1 of the Sahara desert were
covered with the solar cells just described, it would more than
supply our worlds current energy needs. We will briefly outline
some of the processes and materials that are now being researched
for converting the use of solar energy into electricity.
Homemade Solar Cells # 401
You should have no trouble building the cells that will be
described in the following pages. Be cautious. Use good judgement
and common sense in handling the chemicals and heating
processes described. You'll find that a simple solar cell can be
constructed by a persistent student, Solar cells that can make
outstanding science fair projects.
The electrical output from the homemade copper cells in
this article will be well below that of modern commercial cells,
but the materials cost is also very low. Often a cell can be literally
produced for pennies! The loss in efficiency is probably more
than made up in the reduction of their price.
But again the Screen printed solar cells are far more powerfull
than the copper type solar cells.
COPPER SOLAR CELLS
A small, carefully made solar cell of approximately 2 1/2"
diameter will produce around 5 milliamperes of current in direct
sunlight. This is enough to drive a sensitive light meter or
extremely sensitive relay. Banks of these cells have even been
used to run small electric motors.
Experiment with the procedures described. You may stumble
onto a method of producing even more efficient cells than we have.
Just be sure to be very careful. The chemicals described can be
dangerous if abused or mishandledY. ou build at your own risk!
There are an estimated 80 trillion kilowatts of solar electrical
energy available in the northern hemisphere.
Page 14
An example of a complete Free Energy System, Using Solar cells in series and parallel to charge 12
volt deep cycle batteries, which in turn runs our 5,000 watt inverter to run your home on 120 vac x 60
Hz. We recommend replacing the solar panels with our Fuel less Engine connected to a 12 volt car
alternator to keep up batteries. The lawn mower motor we use as a back up.
Many Different types of Chemicals Have Photoelectric Properties!
There are a number of elements and chemical compounds
that can be used to produce photoelectric power. They include
titanium, selenium, thorium, cuprous oxide, and metals of the
alkali group including sodium, potassium, rubidium, lithium,
cesium and francium.
The two best substances for a homemade cells are, selenium
and cuprous oxide.
Homemade Solar Cells # 401
Page 15
To outside air, Hydrogen
gas outlet. PVC pipe.
12
1/2"
17"
deep
Solar
is
not
a
good
choice!
65"
SIDE
VIEW
120
volts
DC
High
Voltage
DANGER
Solar
Panel
Charge
Control
Inverter
120
volt
DANGER
HIGHLY
EXPLOSIVE
Use
the
options
that
fit
you.
See
our
Fuel
from
water
plans
or
use
our
Fuel
less
Engine.
WATER
glass
jar
Hydrogen
/
oxygen
+
120VDC
CAR
ALTERNATOR
or
use
a
AC
generator
w/diode
and
change
to
120vDC
Charging
system:
charge
for
2
to
3
hrs
per
day!
120 VDC wall outlet
Breaker box with 120 VDC meter.
YOU
MUST
HAVE
AN
ON/OFF
BREAKER
BOX.
YOU
CAN
USE
A
120
Vac
HOUSE
TYPE.
USE
PVC
GREY
PIPE
5,000
WATT
INVERTER
120
vac
x
60
hz
modified
or
pure
sine
wave.
120 VAC OUTSIDE OR INDOOR
BREAKER BOX
Page 16
Homemade Solar Cells # 401
Selenium was extensively used in the production of commercial
solar cells before silicon. Although it can be a somewhat
difficult to find a supplier and it is a toxic heavy metal, it is
relatively inexpensive and can often be found in old model radio
sets, where it was used in the rectifier of the power supply.
A selenium photocell is made from a metal plate
(usually iron)
with one side being covered with a layer of
selenium. A very thin
layer of silver or gold is spattered over the
selenium layer forming
a layer of current-carrying material that
allows light to pass through
it. This layer is called a transparent
electrode. A metal electrode
called a collector, rests on the gold or
silver near the edge of it.
Wires are attached to the collector and the iron plate to deliver
the electric current to the load. Although not as great an output
as more modern cells, a selenium photocell can produce as much
as eight milliamperes for each square inch of surface area exposed
to bright sunlight.
Page 17
Homemade Copper Solar Cells
Homemade Solar Cells # 401
Cadmium sulfide is probably the most promising low-cost
solar cell second only to silicon.
If you have an interest in electronics, you will undoubtedly
recognize cadmium sulfide (the common "CDS" cell) as the
material used in light detecting circuits. Although inventors
have realized for some time that a number of materials such as
cadmium sulfide change their electrical resistance in the presence
of light, it has only been in fairly recent times that it was
realized they could also be used to generate power also.
The most important attribute of cadmium sulfide is that it
could be mass-produced efficiently using a thin-film procedure
wherein very thin layers of its photosensitive components are
evaporated onto a base metal or screen printed.
An Experimental Cell With Cuprous Oxide
The best cell by far for the you to start with, is a cell made
with cuprous oxide (Cu^O). Copper actually has two oxides, a red
Cadmium cells are fairly efficient (3-5 typical) making
them a good rival for amorphous silicon cells.
Homemade Solar Cells # 401
oxide called cuprous oxide, and a black oxide called cupric oxide
(CuO).
The dark red cuprous oxide has photoelectric properties but
black cupric oxide does not. The black oxide that forms on the
outside of your cell must be removed because it is opaque and
will not allow light to reach the cell's active surface.
Building your solar Cell
Step 1. Cut a piece sheet copper into the size and
shape you wish for your cell. Although .025 inch thick copper
was used for the cells described here, just about any thickness
will do.
Copper is a soft metal and can be cut with tin snips or even
with an old pair of scissors.
Cut your cell with a diameter of 1 1/2 inches, we strart with a
smaller cell because it is much easier to work with. The larger
the heat source the bigger the size copper you can use to create
your solar cell. After you get the hang of it you can then build
larger cells..
As you cut the copper, be sure to leave a "handle" so that you
may grip the cell with pliers without marring the cell's active
surface.
Page 18
Page 19
Thin Copper sheet
Homemade Solar Cells # 401
Step 2.
the surface of the cell
must be made extremely
clean. Prepare
a solution of nitric acid
by carefully mixing 20
parts nitric acid and 80
parts distilled water.
Remember towear protective
goggles or other
suitable eye protection
and to work in a well
ventilated area whenever
you work with
chemicals. Copper disk, scoured & polished
and dipped in acid.
IMPORTANT! ALWAYS ADD ACID TO WATER!
NEVER ADD WATER TO ACID!
Begin by carefully polishing the face of the cell with a fine
grade of steel wool until it shines brightly. Then place the cell
with the shiny side up, in the solution of nitric acid.
Soon, tiny bubbles will form on the copper disk. Stir the
solution occasionally. When the disk seems shiny and well
cleaned, remove and rinse it under cool running water.
WARNING! Never to allow your skin to touch the acid, and
that no acid remains on the cell.
The cell will sometimes work without the acid cleaning if it is
simply well polished by the steel wool. However, we strongly
recommend the acid cleaning.
Nitric acid and the other chemicals mentioned in the text can
be easily ordered from a number of mail-order chemical houses
such as found in the classified section of magazines such as
Popular Science.
Step 3. Cuprous oxide is now formed on the disk by heating
it over a Bunsen burner, or propane torch. A gas stove can be
used, but results may be unpredictable.
The time me disk must be heated varies greatly depending on
the heat of the torch, and the thickness and size of the copper
piece. Using a standard propane torch from the hardware store
and a disk of the described size, I found 2 minutes and 40 seconds
to be ideal. If you heat it too long, you run the risk of burning off
the oxides. Heating for too short a time may prevent the oxides
from forming fully.
Page 20
Homemade Solar Cells # 401
Page 21
Photo sensitive oxides are
formed by heating the disk
for several minutes.
The Copper is heated on one side only, until it is glowing and red hot!
copper must be kept at an even red hot,all over it's surface for about
2 minutes and 45 seconds by moving the copper over the tourch in a
round motion. counter clock wise. The side of the cell that is not exposed
to the flame will become coated with the black cupric oxide.
Copper Disk
Homemade Solar Cells # 401
Homemade Solar Cells # 401
What has worked very well for me is to bring the cell's temperature down
as slowly as possible making sure the black oxide does not crack at all. Once
completely cool, the cell is immersed in the nitric acid bath. You must wait
while the acid begins to dissolve the black oxide. Then you remove and rinse
the cell.
After heating your cell for theprescribed time, it must be carefully cooled.
There are two ways to go about this. You can cool the copper quickly by
either placing it face down on a flat metal surface, or by waiting a few moments
and then quenching it in cool water. The advantage to cooling the cell
quickly is that the unwanted black cupric oxide will often flake off the cell
due to the difference in contraction rates of the oxides. Unfortunately, I have
had bad luck with this method despite extensive experimentation with different
temperatures and procedures.
Now just beneath this black oxide is the photo sensitive red cuprouse oxide.
This red cuprouse oxide can be purchsed in powder form and mixed with a
special solvent, which is clear, and is described in the Japan Patent. The
Oxide can then be screen printed onto the copper surface. This oxide
material is different than the chemicals used in the Patent.
away with steel wool and a little elbow grease. After all of the Black oxide has
been removed, your cell should have a uniform caoting of deep red on one side.
A very weak solution of sodium cyanide can also be used with good results.
However, you should be extremely careful when using it. Cyanide is an extremely
poisonous chemical, and if accidentally mixed with an acid can create
deadly fumes. At this point the black oxide covering the cell can be rubbed
Page 22
black oxide has been removed, your cell should have a uniform coating of deep red on one side. Don't
worry if the very outside
edges of your cell don't have
the coating, this is due to uneven cooling and is normal.
Keep in mind that the red coating must not
be scratched or scraped away to reveal the bare copper plate beneath. If this happens the cell might short in the final
step and not
work at all.
Testing: There are now several ways
that you can test you solar cell even though it is not finished, it can generate power.
If you are building the
cell for a science fair or other
demonstration, you may want to
stop and use the cell at this point
while the
cuprous oxide is still
visible.
If you hold the cell near a source
of bright light, a current will be generated between the cuprous oxide
coating and the copper plate. The copper will form the positive
terminal and the cuprous oxide the negative.
Making
contact with the copper portion of the disk is very easy. Simply sand a small bare spot on the back of the solar cell and attach
a wire. Attaching the wire and making a good contact with the cuprous oxide is more difficult, it is hard to solder and attach anything.
but it can be done by pressure gluing or other.
Page 23
Homemade Solar Cells # 401
method of making a good contact with this large of a surface area, is
by attaching a wire grid to it. A better way is to apply a very thin
layer of silver or gold called a transparent
An easily fabricated but temporary transparent electrode can
be made from salt water. Or as seen
in our Chlorine cells and a container glued to the cell and the liquid applied. A soloution of salt or acid will conduct
electricity and also pass
light to the cell. Drip a small amount of
salt water or your spit, on to the center of the cell. Make sure that the water
rests only on the
cuprous oxide and does not touch any of the solar cell's copper surface or it will short out and will not produce any free electrical energy at
all.
Now, attach one wire from a galvanometer, digital voltmeter
using the milliamp or low voltage setting to some exposed portion of
the
cell's copper surface. Usually the back or the edges have
some exposed copper. Touch the other meter lead to the surface
of the water. The
meter will spring to life.
Next, bring a bright source of light such as a 100 watt bulb near
the cell. The meter should show a slightly smaller
voltage as the
light approaches. Your cell will produce best in sunlight! The cell is changing some of the light into
electricity but is having to
counteract the current generated by
the saltwater, hence the drop in voltage. The salt water actually
acts as an electrolyte and with the oxide
generates its own
current just as a small battery would.
Another way that you can test your cell is by making a wire
electrode for the surface.
This is done simply by coiling some 30
gauge silver-plated wire or aluminum wire and by holding it
against the ( cells ) cuprous oxide
surface with a sheet of glass. A good
way is to coil the wire around is to use a cone shaped dowel or other
object first in order to make good even spirals. Make sure that
the wire touches the cuprous oxide only, and none of the bare
copper. You will always have some bare copper around the edges of the cell, so it is best to paint with enamel paint, let dry and then work
with the cell.
By simply attaching one wire of your meter to the silver wire, and one to the cell's
exposed copper, you will be able to register a small
current when
a light is brought near.
In this form, the cell can be operated indefinitely and makes
an excellent Science Fair Display.
Making The Silvering Solution: The final step in making your own solar cell will be to make
a permanent transparent electrode. When
properly applied, this
will give your cell a beautiful semi-mirrored finish and allow
you to make electrical contact with the whole cuprous
oxide face
of the cell.
This step is probably the trickiest in the production of the cell.
Page 24
Homemade Solar Cells # 401
But, just as with the last
steps, it becomes somewhat easier with practice. Using distilled water, make ten percent solutions each of ammonia
water, potassium hydroxide and potassium sodium tartrate in seperate test tubes. A ten percent solution can be created by mixing 10 parts by
weight of solute in 90 parts of water. Please remember that the test
tubes can become warm or even hot when the water is first
added, so be sure to use Pyrex
glass test tubes. Also, make certain
you have ample ventilation when mixing the ammonia solution.
Dissolve in 1 oz. water a single crystal of silver nitrate. The
crystal should be somewhat larger than the head of a match.
Begin adding drops of the ammonia solution to the dissolved
silver nitrate until the water first
becomes brown, and then just
begins to clear.
Add a drop of potassium hydroxide to this solution. Then again begin adding drops
of ammonia water until the
solution just begins to clear. The
solution will remain somewhat cloudy. Too much ammonia
in the solution can dissolve the cuprous oxide coating and can
damage or ruin the cell.
Stir the mixture while adding a single drop of the potassium
sodium tartrate solution.
The mixture is now ready and should be used
immediately.
Applying The Solution
Temperature and variations in the chemical mixture can
dramatically change the time required to complete the silvering
process. The best way to complete this step is by simple visual
examination of the process as it proceeds.
With the cell on a flat surface, begin by carefully pouring the
silvering mixture on to the center of the cell. Remember to avoid
letting this mixture contact any exposed copper. A good trick is
to cover with paint or lacquer any exposed copper surfaces on
the face of the cell.
Continue pouring until the liquid has covered as much of the
surface as you can . If all the exposed copper on the surface has
been properly protected with the lacquer, you can actually pour
the solution until it comes right to the edge. Since water has an
affinity for itself
called "cohesion", it won't spill over the edge.
Very soon, a thin film of silver will begin to form over the cell's
surface. The liquid should be
poured off when the red oxide is
still slightly visible beneath the silver. allow the silvering process to go a little too long rather than not
long enough since some of the silver coating can be polished away.You should now have a smooth silver coating through which
the red oxide is barely visible.
Completing the Cell
contact can now be made to the cuprous oxide face of the
ell by means of a ring of lead or silver-coated wire which is
slightly smaller in diameter than the disk itself. With the ring held firmly against the disk, a protective coating of thin lacquer
can be applied. Make certain the lacquer does not come between the wire and the disk. With wires attached to the disk's copper back and the
lead or silver ring, the cell is complete. The disk can now be housed behind glass, mounted to a sheet of plastic, cast in a clear resin or
housed in any other enclosure you desire!
Page 25
Homemade Solar Cells # 401
Homemade Solar Cells # 401
Screen Printing Supplies and Devices
Wood Screen printing Frame(s) Photo Emulsion / premixed
for applying to back side of
screen, ( see our Screen Booklet. )
Wood and special rubber Squeegee
for pulling the ink over the inside of the
wood framed screen to print image.
Wood and special rubber Squeegee
Photo emulsion aluminum screen coater
Photo emulsion aluminum screen coater’s
for different size wood framed screens. 6 - color t-shirt & cap printing press.
You do not need this to print solar cells,
all you need is a flat and sturdy table top.
Page 26
Crystal properties
Crystal growth method: Seeded vapor phase growth
Crystal growth orientation (0001)
Maximum size Up to 50mm diameter
Variations: Doped crystals (on request)
Crystallographic properties
Crystallographic structure: Hexagonal
a= 0.4135nm, c= 0.6749nm
Defects structure Inclusions with < lOu. in size
Color: Red
Physical properties
Density: 4.82 g/cm3
Melting point: 1748 °C
Hardness: 4 Mohs
Thermal conductivity: 15.9 W m -1 K-1
Dielectric constant: 8.28 C, 8.64 | I C
Band gap (@ 300 K ): 2.53 eV
Specific resistivity: ~108 (Ohms cm)
Emmission wavelength: 600 nm @ 300 °K
Optical properties
Transmission range: 0.5 um -15 urn (2mm thick)
Refraction index: No = 2.517, Ne = 2.548
Page 27
Cadmium Sulphide ( CdS )
Homemade Solar Cells # 401
U.S. Patent Jul. 23, 1996 5,538,903
1. Clear glass 2. Electrical Insulation
N-type Cd’s layer = Negative
. Ag.In Electrode, 5&6
An AG.In Electrode
Positive Terminal
P - Type CdTe Layer
SUN
Light
An current collecting carbon
electrode layer silver & Indium mixed
to a printable past. Ag & In
Double or triple print #2, to do this you print the first layer, let dry and then print the
2nd layer = 60 um thickness. #3 layer print only one layer using the same screen
printing screen.
METHOD OF MANUFACTURING SOLAR
CELL
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method of manufacturing a
solar cell of compound semiconductors by way of coating |
and firing.
2. Description of the Prior Art
In recent years, expectations for solar cells as a clean
energy source have been raised, in view of the global
warming, acid rain. ozone layer destruction, and other such
environmental destruction. For the wide usage of solar cells
to occur, improvement of the photo-electric conversion
efficiency and reduction of the cost are most important, that
purpose, solar cells made of compound semiconductors of
Group III-V materials such as GaAs, InP. Group II-VI
materials such as CdS/Cu2S, CdS/CdTe, and Group I-III-
VIa materials such as CuInS2. CuInSe2, as well as crystalline
and amorphous silicon solar cells, have been investigated
in many countries of the world. Among these, solar
cells made of compound semiconductor helerojunctions of
n-CdS/p-CdTe have been produced commercially, with relatively
low material cost, conversion efficiency as high as
10%, less deterioration over long time peniods, and a relatively
simple manufacturing process suitable for mass protuction
consisting of printing, drying, firing ( sintering or
baking), resulting in a high density arrangment on a glass
plate and realization of high voltage without outer wire
connectionon, as well as large area cells.'
A typical solar cell of Group II-VI semiconductor, of
which a sectional view is shown in FIG. 1, comprises a glass
substrate 1 of high light transmittancc and electrical insulation
provided on one surface thereof with an n-type CdS
layer 2, a p-typc CdTe layer 3, a current collecting carbon
electrode layer 4. an Ag.In electrode which is the positive
terminal 5, and an Ag.In electrode which is the negative 40
terminal 6 formed by laminating with printing and baking of
each layer. Usually, although not shown in the figure, the
thus prepared solar cell element is provided, on both the
Ag-In electrodes, with a copper paste layer deposited, dried,
and baked for easy soldering of lead wires. The cell is then
covered all over with a passivation layer of a thermosetting
resin such as epoxy and baked.
Light, including that of the sun, falls on the surface of the
glass substrate 1 opposite to the surface having the above
solar cell element layers, to generate electrical power by
photo-electric conversion.
As the substrate, a heat-resistant barium borosilicate glass
is employed which has a very low alkali metal content and a
high softening point. 55
In the manufacturing of the compound semiconductor
solar cell by the coating and firing method, it is important
that each of the n-type compound semiconductor layer
p-type compound semiconductor layer, and electrode layer
have uniform thickness, a smooth surface. and no pin holes!
Especially if the n-type CdS semiconductor layer formed
directly on the substrate is uniform, smooth and nonporus,
the adherence of the lto the substrate is
improved, resulting in an increase of the light transmittance.
decrease of the sheet resistance, and, further, an increase of
the photo-current and improvement of the characteristics of.
the cell.
2
Conventionally, to obtain such a layer, a paste made of the
powdered compound semiconducterr or elements "therefor, an
eletroconducting agent, and a viscouse agnent mixed |together
was kept under reduced pressure to remove bubbIes therein
and after the deposition, the substrate was held horizontally
at about 50°C., which was lower than the drying temperature
of the viscous agent, to reduce the viscosity of the ~
viscous agent and uniformly precipitate the raw material
powders in order to obtain a high density layer. However, if
the bubbles were removed from the paste before coating, it
sometimes happened in the coating process by screen printing
that bubbles were introduced from the surrounding
'atmosphere, resulting in uneven deposition-or pin-holes.
Also, with the heat treatment only after coating, the raw
material powders did not always uniformly precipitate- and
the bubbles were not sufficiently removed, resulting in the
layer not being fat, or of uniform thickness. The pin-holes
left after coating and firing of the layers caused an Increase
of the sheet resistance. Especially, if pin-holes were formed
in the p-type CdTe layer, the carbon particles of the carbon
electrode layer formed thereon penetrated into the pin-holes
up to the CdS layer under the CdTe layer, causing internal
short circuiting or current leakage, fatally damaging the
solar cell performance.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a new
method of manufacturing compound semiconductor solar
cells comprising ntlypc and p-type compound semiconductors
and electrode layers having improved performance,
uniform characteristics, and Iow production cost. brought
about by formation of the layers without pin-holes and with
uniform thicknesses and smooth surfaces.
To obtain the above object, a method of manufacturing a
solar cell according to the present invention comprises thsteps
of forming a layer of an n-type compound semiconductor,
a layer of a p-type compound semiconductor, and an
electrode layer on a glass substrate, wherein at least one of
said steps of forming a layer of compound semiconductor
comprises preparing a paste by mixing a semiconductor raw
material and a viscous agent, applying said paste to said
substrate, drying said paste to harden it and firing said dried
paste, and vibrating said substrate during or after the application
of the paste.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic sectional view of a Group II-VI
compound semiconductor solar cell of n-CdS/p-CdTe type.
FIGS. 2(A)-2(B) are microphotographs of sections of
sintered CdS layers on a glass substrate.
FIGS. 3A-3D are graphs of the open circuit voltages.
short circuit currents, fill factors, and intrinsic photoelectric
conversion efficiencies of solar cells fabricated according to
the present invention, as well as by the conventional method.
DETAILED DESCRIPTION OF THE
INVENTION
An example of the method of manufacturing a Group
II-VI compound semiconductor solar cell according to the
present invention is now explained by referring to FIG. 1.
A paste was prepared by mixing a fine powder of cadmium
sulphide (CdS), cadmium chloride (CdCI2). and pro.
pylene glycol (PG). the CdC12 being a flux. and the PG being
a viscous agent.
U.S. Patent Jul. 23, 1996 5,538,903
Homemade Solar Cells # 401
Screen Printing
© Copyright 2003
Learn how to Screen Print. Screen printing is done
all over the world by very large printing companies
right down to the guy who does it at home in his
basement. Screen printing was first discovered by
the Chinese hundreds of years ago. It is a very
simple process that anyone can do. The Chinese first
used silk to use in there wood frames to print with,
then as time went on better material was made to
print with
Homemade Solar Cells # 401
Homemade Solar Cells # 401
See our Screen printing video or Screen printing booklet
Video only $29.95 #402video, Booklet only $9.95
Photowatt chooses Dupont's Solamet™ materials for its PV solar
cells
For many years, Photowatt has been a European leader in the manufacture of
photovoltaic (PV) solar cells. Since 1997, the company, based at Bourgoin-Jallieu, near
Lyon, France, has been a part of ATS (Automation Tooling Systems), a large
multinational concern with its headquarters in Toronto, Canada. ATS specializes in the
fabrication of automated production lines for the automotive and electronics industries.
ATS's fully-automated solar cell lines
The company's parent, ATS, has a strong background in the automation of
manufacturing processes. This has enabled Photowatt to install two new fullyautomated
high volume PV cell and module manufacturing lines which are shown in the
photo on the right. These lines started operating in 2000 and can undertake the screen
printing of the rear and front metallisation pastes, drying and firing of the pastes,
deposition of the anti-reflective coating (ARC), sorting, ribbon soldering, lamination of
the protective insulation layer and module assembly.
Today, the standard size of a multi-crystalline Si cell is 125 x 125 mm (5 inches square)
with a thickness of 300 Mm. Using a titanium dioxide anti-reflective coating, Photowatt's
solar cell efficiency was about 13 per cent. More recently, using new silicon nitride antireflective
coating technology, this efficiency has been improved to over 15 per cent on
the company's own multi-crystalline silicon. DuPont Microclrcuit Materials has been
In 2001, the PV market grew by 39 per cent,
based on power in megawatts (MWp), and
Photowatt is well positioned to take
advantage of this buoyant market. Like most
large PV manufacturers, the company has
increased capacity every year to cope with
demand and, between 1995 and 2002, its
production capacity has increased 10-fold,
from 2 to 20 MW.
Photowatt has an advantage in the industry
by being a vertically-integrated PV cell
manufacturer with the capability to produce
solar panels from silicon feedstock. It can
therefore control all of the intermediate
processing and manufacturing steps,
including ingot casting, silicon wire sawing,
solar cell metallisation, lamination and
assembly.
Homemade Solar Cells # 401
Learn How to Screen Print
Start your Own Business, Be your own BOSS!
Make up to $100,000 per year
Screen Printing plans / booklet ........................only # 402Book
Start your own Business It's Easy!
Start Your Own Screen Printing Business Right in your Own Home!
Screen print T-Shirts, Caps, Jackets, Signs, Bumper Stickers, etc...
Save money by building all homemade screens and special table top printer! Get started as low
as $70
Included is where to buy T-Shirts, Caps, Supplies etc... Wholesale!
Also great for Screen printing solar cells! Screen print as many Solar cells as you want for you
and your friends, Screen printing Booklet teaches anyone to screen print in there own backyard
it's easy to do! Print as many solar cells as you want for just pennies! Stop paying high electric
bills. You may even want to start your own screen printing and sign business, printing t-shirts,
caps, jackets, decals, and signs of all types, make big money, our video and booklet will show
you how!
$9.95
Screen Printing Video (vhs) ...........................only $29.95 # 402Video
This video is packed full of information and shows you how to get started in screen printing and
shows an actual 5-color t-shirt printing press being used, how to make and prepare a screen, what
type of ink to buy, and where to buy your screen printing supplies, where to buy your t-shirts,
jackets and caps at a low wholesale price.. Some companies sell small screen printing kit's for
only $28.
Build a 5/color T-Shirt Printing Press!.
Start your Own Business, Be your own BOSS!
Make up to $100,000 per year
Plans only.................................. $19.95 # JC-M1..
Homemade Solar Cells # 401
Homemade Solar Cells # 401
NOTES
Homemade Solar Cells # 401
NOTES
Homemade Solar Cells # 401
NOTES
Homemade Solar Cells # 401
NOTES
Homemade Solar Cells # 401
NOTES
Homemade Solar Cells # 401
NOTES
Homemade Solar Cells # 401
NOTES
Homemade Solar Cells # 401
NOTES
Homemade Solar Cells # 401
NOTES
Homemade Solar Cells # 401
NOTES
mSeomlaader Cells Ho
C Copyright 2003
BATTERY
VOLTS AMPS
OVER
TEMP
OVER
LOAD
# 401P
for
Time is running out
FREE ENERGY
2003
CREATIVE SCIENCE P.O. BOX 557 NEW ALBANY, IN. 47151
www.fuelless.com .wfuwewllesspower.com
401cvr
www.fuelless.com .wfuwewllesspower.com
SCIENCE
Creative
& Research
PO BOX 557 New Albany, IN. 47151 USA
Copyright 2002 - 2004 Creative Science & Research
# 401P
C Copyright 2003
Thank you for buying these plans. It will help us in our research efforts and to tell the world about this
suppressed technology.
Included is 3 different ways to make a home made solar cell:
The 1996 japan Patent is by far the best and the most powerful. The japan patent uses a simple process that has
been used for centuries, You simply screen print the negative and positive layers and the contact layers on to a
piece of glass plate, it does not matter how thick the glass is. The layers can be sprayed on with a spray gun
and a air compressor, but it is best to Screen print it. Screen printing each layer will make your solar cells last
longer and they will be more efficient
If you do not know what screen printing is, you can learn about this very simple process from the Library.
Also lots of info and supplies can be purchased at your local hobby store or art supply store. You can also buy
supply's such as screens and such at a local Screen printing shop. or they can screen print it for you. Screen
printing is very simple and cheap to do for you self right in your own home. It may take a little studying but it
will be worth it. you can print up as many Solar Cells as you want for just pennies. ( Cover your entire roof
with them. You will have more energy than you will ever need. You can then make money selling electricity
back to the electric company which should pay for it self in one to two years. The most expensive part is the
deep cycle marine batteries and your inverters. Many are making a nice income every year from this, just by
selling electricity back to the electric company, ask to see if your electric company has that type of program in
your area. most states I heard do.
The Japan method is new and it is not limited to just a glass surface, you can also apply it right onto
aluminum or copper sheeting. Look at the 1 st page, see the N type layer #2 this is what the Patent says to
Print first. But if you want to print onto a metal surface the metal surface would be #5 then the 1 st print would
be #4 then let it air dry and then bake at 600 degrees for 3 to 5 minutes.
(Each printed layer can be done this way.) Then your 2nd print would be #3, then you let air dry, then bake,
then Print #2 Air dry/bake. Then you must print a Metal grid over #2 then let air dry, (you don't have to bake
the metal print. ) This will be your negative contact, #5 will be your Positive Contact, so what your doing is
just simply reversing the printing layer steps. If you have never seen a solar cell the metal grid is like a metal
door screen but with bigger spacing. You can buy a special metal printing ink or mix it your self as the patent
says. The ink is simply made up of nickel or silver. Nickel is the cheapest and will work just fine.
Please Notice: You can not manufacture and sell the Japan Solar Cells with out there permission If you want
to leam about Screen Printing we sell a VHS Video for only $29.95
Please send $4 for shipping.
The chemicals that are mentioned in the patent are very easy to get. You can buy them in any QTY from any
Chemical supply company look one up in your yellow page phone book. Or check online, search for Chemical
Supply Shops or companies.
Homemade Solar Cells # 401
Page1
Homemade Solar Cells # 401
About Photovoltaics
Photovoltaic (or PV, Solar Cells ) systems convert light energy into electricity. The term "photo" is from the
Greek "phos" which means light. "Volt" is named from Alessandro Volta (1745-1827, He was a pioneer in
the study of electricity. So you could say that" Photo-voltaics is basically light electricity! And is most
commonly known as Solar Cells. Solar cell systems are already a very important part of our lives. The
simplest systems power many of the small calculators and wrist watches we use everyday. PV power is the
cheapest form of electricity for powering these small devices. There are many ways to make solar cells, and
one of the cheapest ways is to screen print them. There are many companies in the USA that are doing this.
Many US Patents have been issued for screen printing solar cells and there are many different chemical inks
that can be used. The Japanese Patent is one of many.
Page 2
Turning Sunlight Into Electricity!
Solar Cells convert light energy into electricity at
the atomic level. It was first discovered in 1839, the
process of producing electric current in a solid
material with the aid of sunlight wasn't truly understood
for more than a hundred years.
Throughout the second half of the 20th century, the
science has been refined and process has been more
fully explained. As a result the cost of these devices
has put them into the mainstream of modem energy
producers. This was caused in part by advances in
technology, where PV conversion efficiencies have
been improved.
Solar Cell Materials
The most important parts of a solar cell are the
semiconductor layers, this is where the electron
current is created. There are a number of different
materials available for making these semiconducting
layers, and each has benefits and drawbacks.
Unfortunately, there is no one ideal material for all
types of cells and applications.
In addition to the semiconducting materials, solar
cells consist of a top metallic grid or other electrical
contact to collect electrons from the semiconductor
and transfer them to the external load, and a back
contact layer to complete the electrical circuit.
Then, on top of the complete cell is typically a glass
cover or other type of transparent encapsulant to
seal the cell and keep weather out, and a antireflective
coating to keep the cell from reflecting the
light back away from the cell. A typical solar cell
consists of a cover glass, a anti-reflective layer, a
front contact to allow the electrons to enter a circuit
and a back contact to allow them to complete the
circuit, and the semiconductor layers where the
electrons begin to complete there voyages!
Homemade Solar Cells # 401
Page 3
12” x 18” 12 vdc
Screen Printed Solar Cells
Scientists in Arizona are using screen-printing, a
technique developed for printing fabrics, paper and
to produce plastic, glass and metal solar cells.
The basic materials of a photovoltaic cell (solar cell)
are inexpensive. The organic manufactured by
Ghassan Jabbour and colleagues at the University of
Arizona in Tucson have about 11/4 of the efficiency
of commercial silicon solar cells, which turn 10-20
per cent of light energy into electricity. But, being
cheap to produce, they can make up the loss in
quantity what they lack in quality. Now the Japan
screen printed solar cells are even better than that!
For more info contact: Matsushita Electric Industrial
co. LTD, Osaka. Japan
In conventional Screen - printing, a taut piece of
screen mesh fabric is stretched over a wood frame,
you can buy the screens already made and the materials
from any screen printing shop or screen printing supply
company in your area or on the internet. Also you might
want to check with your local art store, sometimes they
have full kits etc...
The screen is then masked off using masking tape,
For example: a 5" x 5" square area. the screen outside
of the masking tape is then coated with a block out
liquid or paint, this is so when you apply your semiconducting ink that you mixe, it will go
through just the area that you masked off when you apply a rubber squeegee to it. The
screen can then be placed on any table top and hinges attached to the back of the wood
frame and the table, this will insure the screen can move up and down. Then get a small
wood paint stick and using a small nail, hammer one end to the front side of wood frame.
This will be your kick leg and will help keep your screen in an upward position when
needed. Take a 5" x 5" piece of glass and place it right under the open 5" x 5" area of the
open screen mesh. When the leg is flipped back the screen comes down and you grab
your rubber and wood handled squeegee and with the ink in front of your rubber squeegee
pull toward you applying pressure so ink will go through screen, once you have passed by
the 5" x 5" area then flip the screen back up and reverse squeegee to flood the screen for
the next print.
Homemade Solar Cells # 401
A Screen printing press, the
wood frame is the screen
An example of a Silicon cell
Page 4
The Research group mentioned earlier, Jabbour's group, print very flat,
thin cells, onto glass in a similar way. First they coat the glass with a
transparent electrically conducting material (metal ink) that acts as one of the
solar cell's electrodes. On top of this, they lay down a thin film of a polymer,
which helps to gather current from the photovoltaic material.
Finally they deposit a blend of two organic compounds that convert light into
electricity. One is a carbon-based molecule called a fullerene, it produces
charged particles that carry an electrical current when light shines onto the
molecules. The other is a polymer, it ferries the current to the electrodes on
the top and the bottom of the solar cell.
Under blue light, these screen-printed solar cells have an efficiency of 4.3 per
cent. And the Japanese cells are much greater than that! Many of the flexible
solar cell panels that you see today are screen printed.
Now lets take a look at what The Dupont Company is doing with there solar
cells. Dupont is involved in the development of solar cell metallisation since
the 1970's. Although all PV cell manufacturers use different processes to
make there solar cells, the metallisation of the rear and front sides is in many
cases DONE BY SCREEN PRINTING! Which has shown itself to be one
of the most economic way to produce solar cells.
Recently, Dupont achieved a real breakthrough in the formulation of front-side
contacts for silicon solar cells that has resulted in customers, such as
photowatt, to realize the screen printing efficiency by changing their antireflection
technology from titanium dioxide to silicon nitride. This came at
just the right time for the Photowatt solar cell company, Because they have
been using there own past material for the front side metallisation since it first
started manufacturing solar cells. The development of the metallisation from
Dupont for the back side, (p-side). These pasty inks are either silver pastes
containing Al, or pure Al pastes to secure a good ohmic contact with the pside
of the solar cell. We have told you all this to help you better understand
and leam the screen printing solar cell process and what others are doing.
Homemade Solar Cells # 401
Page 5
The Japan Solar Cell Patent
Note: You can Use an outside Grill to bake the Screen Printed layers. It is a good
idea to make small cells, 8" x 10" or what ever. It is easier to fit into the Grill,
We suggest Baking in side a large roasting pan and then put the roasting pan inside
the preheated grill and shut the lid. It is suggested that you try and make 3 prototype
cells first, Work out all the details, Test them, and then start on a large production of
Solar Cells. It will all get much easier once you have done it. It is also suggested that
you bake them out side. You don't want any fumes in the house, an outside grill is the
best and most readily available oven there is and propane is cheap. I hear you may be
able to make them without a Nitrogen atmosphere if not try special gas companies or
make some yourself, it is supposed to be nonflammable.
Screen Printing: You start with a small 14" x 14" wood frame 2x2". Then a plastic
or clothe screen is stretched over the frame tightly one side at a time, and then stapled
down on all 4 sides, we suggest buying a yellow 200 mesh screen from a screen
printing supplier, Then you put an image of what ever you want to print into the
screen by photo emulsion or by cutting a lacquer or water film with an exacto knife.
( see our Screen Printing Video ) Once you have your image you place the finished
screen onto a flat smooth table top, attach it to a 14" long 2" x 4" with 2 door hinges.
using wood screws, then you attach the 2" x 4" on to the table so it and the screen will
not move. the screen should only go up or down.
you then put your 8" x 10" glass under the screen, register it, then lay the screen
down over the glass and apply your ink and then with a small 12" rubber Squeegee,
You pull the ink over the image and it is pushed thru the screen mesh and thru the
image that you cut and smoothly is printed onto the glass.
SUPPLIERS;
Screen Printing Books and supplies; NDS 1-800-783-3883 Indianapolis, IN.
( See also Art Store's, Hobby Shop's, Arts and Crafts, Screen printing company's.)
They also sell copper sheeting.
Solar Cell Screen Print Chemicals: Search the web, simply type in the chemical
you are looking for and many suppliers will pop up. Example: Cadmium Sulphide
Supplier..... We have checked and you can find all the chemicals and info on them
free on the web.
Also see: www.stanfordmaterials.com/semi.html
Homemade Solar Cells # 401
Page 6
Homemade Solar Cells # 401
The Stanford Materials Company
1. Cadmium Sulphide in powder form = Cds (or if already thick liquid or ink OK.)
2. Cadmium Chloride + Cdcl 2 ( Powder or liquid form )
3. Propylene glycol + pg in liquid form
4. Carbon Powder, if you can not find none make your own wood carbon powder?
5. Cadmium = Cd
6. Tellurium = Te
Page 7
THE COPPER CHLORINE SOLAR CELL: Buy a roll of Thin Copper sheeting, cut
a 1.5" diameter piece out with a pair of cutters, then sand polish the copper on both sides
with some fine grade steel wool. then by using a propane torch heat the copper while
griping it with rubber handled pliers, and let the copper get red hot, until it glows, move
the copper over the flame evenly for about 3 minutes then allow to cool slowly. Then
once it is cooled dip it down in an acid solution of 1/2 water and 1/2 acid, WARNING!
Never pour water into acid always pour acid into water. The acid that you can use is
MURIATIC ACID ( Hydrochloric Acid ) you can buy it at any hardware store, or you
can use a solution of nitric acid. REMEMBER TO WEAR PROTECTIVE
GOGGLES OR OTHER SUITABLE EYE PROTECTION, AND WORK IN A
WELL VENTILATED AREA. DO NOT SMELL THE FUMES OR MAKE
CONTACT WITH YOUR SKIN, WEAR RUBBER GLOVES. THESE ACIDS
CAUSE SEVERE BURNS. KEEP OUT OF THE REACH OF CHILDREN.
NOTICE: WE ARE NOT RESPONSIBLE FOR ANYTHING IN THESE PLANS ,
YOU BUILD AND EXPERIMENT AT YOUR OWN RISK.
Keep it in the acid for only a half a minute or longer, the idea is to keep it dipped in the
acid long enough for the black oxide to come off of the top layer, under that is the photo
sensitive red cuprous oxide. Remember you should only have a dark bright red layer left.
Note: do not leave it in to long it will eat away the red. once you have done that then it's
O.K. to wash off the acid with water, do all of this outside or in your garage, make sure
all of the acid is off. wash no less than 3 minutes, now look at the copper disk on one
side you will have bright copper, this is the positive side, and on the other side you will
have red this the negative side the side you face toward the sun. now mix a small
solution of 95 water and 5 Clorox bleach, now take the red side and look for
scratches if there are any you must paint them with enamel oil base paint, apply paint to
any where on that side where copper is showing through, now glue a plastic lid on to red
side, let it dry them drill a small hole in the top pour in Clorox bleach and water solution
and then place a copper or steel wire through the hole and onto the bottom, wire must be
submerged in the solution, now tape or glue the hole up with the wire in it. now tape
Solar cell out into the sun and using a DC volt meter attach + to the copper back, and - to
the steel wire coming out of hole. you will see the meter move showing a voltage, now
block the sun with your hand and watch the voltage drop.
make many of these for just pennies and put them in series or parallel to increase your
voltage or amperage. These type of cells are only 5 of the japan cells.
I have heard that the Japanese cells are about 95 of the American made silicon cell that
is a very expensive process. Screen printing them is the cheapest way to go and is easy,
once you get the hang of it.
Homemade Solar Cells # 401
Copyright 2003 /all pages
Page 8
Chemicals: needed: 1. Cadmium Sulphide = cds 2. Cadmium Chloride == cdcl 2
( These can be in powder form ) 3. Propylene Glycol = pg this is used to mix the
powders into a pasty but screen printable liquid ink type. 4. Carbon powder, if you can
not find it make some yourself out of burnt wood etc... 5. Cadmium = cd
6. Tellurium = Te
Page 9
Homemade Solar Cells # 401
Copyright 2003 /all pages
Homemade Solar Cells # 401
There are many different ways to construct these home made cells, the above
drawing shows a wire screen mesh that you can buy at any hardware store.
Using wire mesh makes a much more powerful cell, than just using one
strand of wire. before assembly, attach the wire mesh to the red copper side.
use a small weight in the center of the wire mesh and using clear silicon, glue
down the edges, ( make sure you don't get any glue in the area where the
plastic cap is going to sit. ) now let that sit over night, then glue on your clear
plastic cap on to the red copper side of cell.
these also make a great science fair project as well as providing free electricity
to your home. It's going to take some practice if you do any of these projects.
but will be able to make your own FREE Electricity force us out of the closet
so they could shut us down.
+
-
Wire
screen
mesh
(
Hardware
Store
)
Glue Clear
plastic
cap
or
glass
container
Copper Chorline Solar Cell
Negative Wire
Positive Wire
Page 10
Knowledge is Power! Study this Patent well and read all
you can from the free info on the internet as well about
screen printing solar cells and the many different chemicals
that can be used! The Japan Solar Cells are better to make
and will last a long time!
Creative Science & Research: PO BOX 557 New Albany IN, 47151
www.fuelless.com www.fuellesspower.com
Homemade Solar Cells # 401
Page 11
A More Simplified Copper
Solar Cell
Similar to the Copper Chlorine Cells. We have found that if you use Conductive Nickle Paint you will
get far better results. But start out using the screen mesh or the aluminum wire. You can buy Nickle
Paint on the internet. Simply search for “ Nickle Paint suppliers “ on your search engine. You can do
the same for finding thin copper sheeting. There is also a company in Louisville KY, that sells copper
sheeting, see Conner Manufacturing 18th st. Louisville, KY. (502)-587-1387 Or Vendome Copper &
Brass 729 Franklin St. Louisville, KY. 40202 (502) -587-1930
Homemade Solar Cells # 401
Creative Science & Research PO BOX 557 New Albany, IN. 47150
Copyright 2003
Page 12
Warning: You build at your own risk!
The fabrication of a modem solar cell is very complicated and
a delicate process. In most cases, a large silicon ingot is grown
from a small crystal in an extremely clean and sterile environment.
Any dust or particle contamination even down to the
atomic level during the growing process can completely ruin the
ingot. Impurities must typically be kept to one part per billion.
The growing process itself is slow, and the very pure materials
required are extremely costly. Because of this, a single ingot
which is later sliced into thin cells approximately 0.05 centimeters
thick often costs thousands of dollars to produce.
This fact coupled with the general inefficiency (7-14 typically)
of even these modem cells has kept the price of photoelectric
cells too high to be competitive with other sources of power.
Someday, lower cost production techniques together with
higher efficiency will make widespread use of clean, renewable
solar energy possible. Someday solar cells will be a very common
Source of energy, the idea of deriving
electricity directly from
sunlight will continue to excite the
inventor and experimenter.
Page 13
Modern
Homemade Solar Cells # 401
It is well known that if even 1 of the Sahara desert were
covered with the solar cells just described, it would more than
supply our worlds current energy needs. We will briefly outline
some of the processes and materials that are now being researched
for converting the use of solar energy into electricity.
Homemade Solar Cells # 401
You should have no trouble building the cells that will be
described in the following pages. Be cautious. Use good judgement
and common sense in handling the chemicals and heating
processes described. You'll find that a simple solar cell can be
constructed by a persistent student, Solar cells that can make
outstanding science fair projects.
The electrical output from the homemade copper cells in
this article will be well below that of modern commercial cells,
but the materials cost is also very low. Often a cell can be literally
produced for pennies! The loss in efficiency is probably more
than made up in the reduction of their price.
But again the Screen printed solar cells are far more powerfull
than the copper type solar cells.
COPPER SOLAR CELLS
A small, carefully made solar cell of approximately 2 1/2"
diameter will produce around 5 milliamperes of current in direct
sunlight. This is enough to drive a sensitive light meter or
extremely sensitive relay. Banks of these cells have even been
used to run small electric motors.
Experiment with the procedures described. You may stumble
onto a method of producing even more efficient cells than we have.
Just be sure to be very careful. The chemicals described can be
dangerous if abused or mishandledY. ou build at your own risk!
There are an estimated 80 trillion kilowatts of solar electrical
energy available in the northern hemisphere.
Page 14
An example of a complete Free Energy System, Using Solar cells in series and parallel to charge 12
volt deep cycle batteries, which in turn runs our 5,000 watt inverter to run your home on 120 vac x 60
Hz. We recommend replacing the solar panels with our Fuel less Engine connected to a 12 volt car
alternator to keep up batteries. The lawn mower motor we use as a back up.
Many Different types of Chemicals Have Photoelectric Properties!
There are a number of elements and chemical compounds
that can be used to produce photoelectric power. They include
titanium, selenium, thorium, cuprous oxide, and metals of the
alkali group including sodium, potassium, rubidium, lithium,
cesium and francium.
The two best substances for a homemade cells are, selenium
and cuprous oxide.
Homemade Solar Cells # 401
Page 15
To outside air, Hydrogen
gas outlet. PVC pipe.
12
1/2"
17"
deep
Solar
is
not
a
good
choice!
65"
SIDE
VIEW
120
volts
DC
High
Voltage
DANGER
Solar
Panel
Charge
Control
Inverter
120
volt
DANGER
HIGHLY
EXPLOSIVE
Use
the
options
that
fit
you.
See
our
Fuel
from
water
plans
or
use
our
Fuel
less
Engine.
WATER
glass
jar
Hydrogen
/
oxygen
+
120VDC
CAR
ALTERNATOR
or
use
a
AC
generator
w/diode
and
change
to
120vDC
Charging
system:
charge
for
2
to
3
hrs
per
day!
120 VDC wall outlet
Breaker box with 120 VDC meter.
YOU
MUST
HAVE
AN
ON/OFF
BREAKER
BOX.
YOU
CAN
USE
A
120
Vac
HOUSE
TYPE.
USE
PVC
GREY
PIPE
5,000
WATT
INVERTER
120
vac
x
60
hz
modified
or
pure
sine
wave.
120 VAC OUTSIDE OR INDOOR
BREAKER BOX
Page 16
Homemade Solar Cells # 401
Selenium was extensively used in the production of commercial
solar cells before silicon. Although it can be a somewhat
difficult to find a supplier and it is a toxic heavy metal, it is
relatively inexpensive and can often be found in old model radio
sets, where it was used in the rectifier of the power supply.
A selenium photocell is made from a metal plate
(usually iron)
with one side being covered with a layer of
selenium. A very thin
layer of silver or gold is spattered over the
selenium layer forming
a layer of current-carrying material that
allows light to pass through
it. This layer is called a transparent
electrode. A metal electrode
called a collector, rests on the gold or
silver near the edge of it.
Wires are attached to the collector and the iron plate to deliver
the electric current to the load. Although not as great an output
as more modern cells, a selenium photocell can produce as much
as eight milliamperes for each square inch of surface area exposed
to bright sunlight.
Page 17
Homemade Copper Solar Cells
Homemade Solar Cells # 401
Cadmium sulfide is probably the most promising low-cost
solar cell second only to silicon.
If you have an interest in electronics, you will undoubtedly
recognize cadmium sulfide (the common "CDS" cell) as the
material used in light detecting circuits. Although inventors
have realized for some time that a number of materials such as
cadmium sulfide change their electrical resistance in the presence
of light, it has only been in fairly recent times that it was
realized they could also be used to generate power also.
The most important attribute of cadmium sulfide is that it
could be mass-produced efficiently using a thin-film procedure
wherein very thin layers of its photosensitive components are
evaporated onto a base metal or screen printed.
An Experimental Cell With Cuprous Oxide
The best cell by far for the you to start with, is a cell made
with cuprous oxide (Cu^O). Copper actually has two oxides, a red
Cadmium cells are fairly efficient (3-5 typical) making
them a good rival for amorphous silicon cells.
Homemade Solar Cells # 401
oxide called cuprous oxide, and a black oxide called cupric oxide
(CuO).
The dark red cuprous oxide has photoelectric properties but
black cupric oxide does not. The black oxide that forms on the
outside of your cell must be removed because it is opaque and
will not allow light to reach the cell's active surface.
Building your solar Cell
Step 1. Cut a piece sheet copper into the size and
shape you wish for your cell. Although .025 inch thick copper
was used for the cells described here, just about any thickness
will do.
Copper is a soft metal and can be cut with tin snips or even
with an old pair of scissors.
Cut your cell with a diameter of 1 1/2 inches, we strart with a
smaller cell because it is much easier to work with. The larger
the heat source the bigger the size copper you can use to create
your solar cell. After you get the hang of it you can then build
larger cells..
As you cut the copper, be sure to leave a "handle" so that you
may grip the cell with pliers without marring the cell's active
surface.
Page 18
Page 19
Thin Copper sheet
Homemade Solar Cells # 401
Step 2.
the surface of the cell
must be made extremely
clean. Prepare
a solution of nitric acid
by carefully mixing 20
parts nitric acid and 80
parts distilled water.
Remember towear protective
goggles or other
suitable eye protection
and to work in a well
ventilated area whenever
you work with
chemicals. Copper disk, scoured & polished
and dipped in acid.
IMPORTANT! ALWAYS ADD ACID TO WATER!
NEVER ADD WATER TO ACID!
Begin by carefully polishing the face of the cell with a fine
grade of steel wool until it shines brightly. Then place the cell
with the shiny side up, in the solution of nitric acid.
Soon, tiny bubbles will form on the copper disk. Stir the
solution occasionally. When the disk seems shiny and well
cleaned, remove and rinse it under cool running water.
WARNING! Never to allow your skin to touch the acid, and
that no acid remains on the cell.
The cell will sometimes work without the acid cleaning if it is
simply well polished by the steel wool. However, we strongly
recommend the acid cleaning.
Nitric acid and the other chemicals mentioned in the text can
be easily ordered from a number of mail-order chemical houses
such as found in the classified section of magazines such as
Popular Science.
Step 3. Cuprous oxide is now formed on the disk by heating
it over a Bunsen burner, or propane torch. A gas stove can be
used, but results may be unpredictable.
The time me disk must be heated varies greatly depending on
the heat of the torch, and the thickness and size of the copper
piece. Using a standard propane torch from the hardware store
and a disk of the described size, I found 2 minutes and 40 seconds
to be ideal. If you heat it too long, you run the risk of burning off
the oxides. Heating for too short a time may prevent the oxides
from forming fully.
Page 20
Homemade Solar Cells # 401
Page 21
Photo sensitive oxides are
formed by heating the disk
for several minutes.
The Copper is heated on one side only, until it is glowing and red hot!
copper must be kept at an even red hot,all over it's surface for about
2 minutes and 45 seconds by moving the copper over the tourch in a
round motion. counter clock wise. The side of the cell that is not exposed
to the flame will become coated with the black cupric oxide.
Copper Disk
Homemade Solar Cells # 401
Homemade Solar Cells # 401
What has worked very well for me is to bring the cell's temperature down
as slowly as possible making sure the black oxide does not crack at all. Once
completely cool, the cell is immersed in the nitric acid bath. You must wait
while the acid begins to dissolve the black oxide. Then you remove and rinse
the cell.
After heating your cell for theprescribed time, it must be carefully cooled.
There are two ways to go about this. You can cool the copper quickly by
either placing it face down on a flat metal surface, or by waiting a few moments
and then quenching it in cool water. The advantage to cooling the cell
quickly is that the unwanted black cupric oxide will often flake off the cell
due to the difference in contraction rates of the oxides. Unfortunately, I have
had bad luck with this method despite extensive experimentation with different
temperatures and procedures.
Now just beneath this black oxide is the photo sensitive red cuprouse oxide.
This red cuprouse oxide can be purchsed in powder form and mixed with a
special solvent, which is clear, and is described in the Japan Patent. The
Oxide can then be screen printed onto the copper surface. This oxide
material is different than the chemicals used in the Patent.
away with steel wool and a little elbow grease. After all of the Black oxide has
been removed, your cell should have a uniform caoting of deep red on one side.
A very weak solution of sodium cyanide can also be used with good results.
However, you should be extremely careful when using it. Cyanide is an extremely
poisonous chemical, and if accidentally mixed with an acid can create
deadly fumes. At this point the black oxide covering the cell can be rubbed
Page 22
black oxide has been removed, your cell should have a uniform coating of deep red on one side. Don't
worry if the very outside
edges of your cell don't have
the coating, this is due to uneven cooling and is normal.
Keep in mind that the red coating must not
be scratched or scraped away to reveal the bare copper plate beneath. If this happens the cell might short in the final
step and not
work at all.
Testing: There are now several ways
that you can test you solar cell even though it is not finished, it can generate power.
If you are building the
cell for a science fair or other
demonstration, you may want to
stop and use the cell at this point
while the
cuprous oxide is still
visible.
If you hold the cell near a source
of bright light, a current will be generated between the cuprous oxide
coating and the copper plate. The copper will form the positive
terminal and the cuprous oxide the negative.
Making
contact with the copper portion of the disk is very easy. Simply sand a small bare spot on the back of the solar cell and attach
a wire. Attaching the wire and making a good contact with the cuprous oxide is more difficult, it is hard to solder and attach anything.
but it can be done by pressure gluing or other.
Page 23
Homemade Solar Cells # 401
method of making a good contact with this large of a surface area, is
by attaching a wire grid to it. A better way is to apply a very thin
layer of silver or gold called a transparent
An easily fabricated but temporary transparent electrode can
be made from salt water. Or as seen
in our Chlorine cells and a container glued to the cell and the liquid applied. A soloution of salt or acid will conduct
electricity and also pass
light to the cell. Drip a small amount of
salt water or your spit, on to the center of the cell. Make sure that the water
rests only on the
cuprous oxide and does not touch any of the solar cell's copper surface or it will short out and will not produce any free electrical energy at
all.
Now, attach one wire from a galvanometer, digital voltmeter
using the milliamp or low voltage setting to some exposed portion of
the
cell's copper surface. Usually the back or the edges have
some exposed copper. Touch the other meter lead to the surface
of the water. The
meter will spring to life.
Next, bring a bright source of light such as a 100 watt bulb near
the cell. The meter should show a slightly smaller
voltage as the
light approaches. Your cell will produce best in sunlight! The cell is changing some of the light into
electricity but is having to
counteract the current generated by
the saltwater, hence the drop in voltage. The salt water actually
acts as an electrolyte and with the oxide
generates its own
current just as a small battery would.
Another way that you can test your cell is by making a wire
electrode for the surface.
This is done simply by coiling some 30
gauge silver-plated wire or aluminum wire and by holding it
against the ( cells ) cuprous oxide
surface with a sheet of glass. A good
way is to coil the wire around is to use a cone shaped dowel or other
object first in order to make good even spirals. Make sure that
the wire touches the cuprous oxide only, and none of the bare
copper. You will always have some bare copper around the edges of the cell, so it is best to paint with enamel paint, let dry and then work
with the cell.
By simply attaching one wire of your meter to the silver wire, and one to the cell's
exposed copper, you will be able to register a small
current when
a light is brought near.
In this form, the cell can be operated indefinitely and makes
an excellent Science Fair Display.
Making The Silvering Solution: The final step in making your own solar cell will be to make
a permanent transparent electrode. When
properly applied, this
will give your cell a beautiful semi-mirrored finish and allow
you to make electrical contact with the whole cuprous
oxide face
of the cell.
This step is probably the trickiest in the production of the cell.
Page 24
Homemade Solar Cells # 401
But, just as with the last
steps, it becomes somewhat easier with practice. Using distilled water, make ten percent solutions each of ammonia
water, potassium hydroxide and potassium sodium tartrate in seperate test tubes. A ten percent solution can be created by mixing 10 parts by
weight of solute in 90 parts of water. Please remember that the test
tubes can become warm or even hot when the water is first
added, so be sure to use Pyrex
glass test tubes. Also, make certain
you have ample ventilation when mixing the ammonia solution.
Dissolve in 1 oz. water a single crystal of silver nitrate. The
crystal should be somewhat larger than the head of a match.
Begin adding drops of the ammonia solution to the dissolved
silver nitrate until the water first
becomes brown, and then just
begins to clear.
Add a drop of potassium hydroxide to this solution. Then again begin adding drops
of ammonia water until the
solution just begins to clear. The
solution will remain somewhat cloudy. Too much ammonia
in the solution can dissolve the cuprous oxide coating and can
damage or ruin the cell.
Stir the mixture while adding a single drop of the potassium
sodium tartrate solution.
The mixture is now ready and should be used
immediately.
Applying The Solution
Temperature and variations in the chemical mixture can
dramatically change the time required to complete the silvering
process. The best way to complete this step is by simple visual
examination of the process as it proceeds.
With the cell on a flat surface, begin by carefully pouring the
silvering mixture on to the center of the cell. Remember to avoid
letting this mixture contact any exposed copper. A good trick is
to cover with paint or lacquer any exposed copper surfaces on
the face of the cell.
Continue pouring until the liquid has covered as much of the
surface as you can . If all the exposed copper on the surface has
been properly protected with the lacquer, you can actually pour
the solution until it comes right to the edge. Since water has an
affinity for itself
called "cohesion", it won't spill over the edge.
Very soon, a thin film of silver will begin to form over the cell's
surface. The liquid should be
poured off when the red oxide is
still slightly visible beneath the silver. allow the silvering process to go a little too long rather than not
long enough since some of the silver coating can be polished away.You should now have a smooth silver coating through which
the red oxide is barely visible.
Completing the Cell
contact can now be made to the cuprous oxide face of the
ell by means of a ring of lead or silver-coated wire which is
slightly smaller in diameter than the disk itself. With the ring held firmly against the disk, a protective coating of thin lacquer
can be applied. Make certain the lacquer does not come between the wire and the disk. With wires attached to the disk's copper back and the
lead or silver ring, the cell is complete. The disk can now be housed behind glass, mounted to a sheet of plastic, cast in a clear resin or
housed in any other enclosure you desire!
Page 25
Homemade Solar Cells # 401
Homemade Solar Cells # 401
Screen Printing Supplies and Devices
Wood Screen printing Frame(s) Photo Emulsion / premixed
for applying to back side of
screen, ( see our Screen Booklet. )
Wood and special rubber Squeegee
for pulling the ink over the inside of the
wood framed screen to print image.
Wood and special rubber Squeegee
Photo emulsion aluminum screen coater
Photo emulsion aluminum screen coater’s
for different size wood framed screens. 6 - color t-shirt & cap printing press.
You do not need this to print solar cells,
all you need is a flat and sturdy table top.
Page 26
Crystal properties
Crystal growth method: Seeded vapor phase growth
Crystal growth orientation (0001)
Maximum size Up to 50mm diameter
Variations: Doped crystals (on request)
Crystallographic properties
Crystallographic structure: Hexagonal
a= 0.4135nm, c= 0.6749nm
Defects structure Inclusions with < lOu. in size
Color: Red
Physical properties
Density: 4.82 g/cm3
Melting point: 1748 °C
Hardness: 4 Mohs
Thermal conductivity: 15.9 W m -1 K-1
Dielectric constant: 8.28 C, 8.64 | I C
Band gap (@ 300 K ): 2.53 eV
Specific resistivity: ~108 (Ohms cm)
Emmission wavelength: 600 nm @ 300 °K
Optical properties
Transmission range: 0.5 um -15 urn (2mm thick)
Refraction index: No = 2.517, Ne = 2.548
Page 27
Cadmium Sulphide ( CdS )
Homemade Solar Cells # 401
U.S. Patent Jul. 23, 1996 5,538,903
1. Clear glass 2. Electrical Insulation
N-type Cd’s layer = Negative
. Ag.In Electrode, 5&6
An AG.In Electrode
Positive Terminal
P - Type CdTe Layer
SUN
Light
An current collecting carbon
electrode layer silver & Indium mixed
to a printable past. Ag & In
Double or triple print #2, to do this you print the first layer, let dry and then print the
2nd layer = 60 um thickness. #3 layer print only one layer using the same screen
printing screen.
METHOD OF MANUFACTURING SOLAR
CELL
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method of manufacturing a
solar cell of compound semiconductors by way of coating |
and firing.
2. Description of the Prior Art
In recent years, expectations for solar cells as a clean
energy source have been raised, in view of the global
warming, acid rain. ozone layer destruction, and other such
environmental destruction. For the wide usage of solar cells
to occur, improvement of the photo-electric conversion
efficiency and reduction of the cost are most important, that
purpose, solar cells made of compound semiconductors of
Group III-V materials such as GaAs, InP. Group II-VI
materials such as CdS/Cu2S, CdS/CdTe, and Group I-III-
VIa materials such as CuInS2. CuInSe2, as well as crystalline
and amorphous silicon solar cells, have been investigated
in many countries of the world. Among these, solar
cells made of compound semiconductor helerojunctions of
n-CdS/p-CdTe have been produced commercially, with relatively
low material cost, conversion efficiency as high as
10%, less deterioration over long time peniods, and a relatively
simple manufacturing process suitable for mass protuction
consisting of printing, drying, firing ( sintering or
baking), resulting in a high density arrangment on a glass
plate and realization of high voltage without outer wire
connectionon, as well as large area cells.'
A typical solar cell of Group II-VI semiconductor, of
which a sectional view is shown in FIG. 1, comprises a glass
substrate 1 of high light transmittancc and electrical insulation
provided on one surface thereof with an n-type CdS
layer 2, a p-typc CdTe layer 3, a current collecting carbon
electrode layer 4. an Ag.In electrode which is the positive
terminal 5, and an Ag.In electrode which is the negative 40
terminal 6 formed by laminating with printing and baking of
each layer. Usually, although not shown in the figure, the
thus prepared solar cell element is provided, on both the
Ag-In electrodes, with a copper paste layer deposited, dried,
and baked for easy soldering of lead wires. The cell is then
covered all over with a passivation layer of a thermosetting
resin such as epoxy and baked.
Light, including that of the sun, falls on the surface of the
glass substrate 1 opposite to the surface having the above
solar cell element layers, to generate electrical power by
photo-electric conversion.
As the substrate, a heat-resistant barium borosilicate glass
is employed which has a very low alkali metal content and a
high softening point. 55
In the manufacturing of the compound semiconductor
solar cell by the coating and firing method, it is important
that each of the n-type compound semiconductor layer
p-type compound semiconductor layer, and electrode layer
have uniform thickness, a smooth surface. and no pin holes!
Especially if the n-type CdS semiconductor layer formed
directly on the substrate is uniform, smooth and nonporus,
the adherence of the lto the substrate is
improved, resulting in an increase of the light transmittance.
decrease of the sheet resistance, and, further, an increase of
the photo-current and improvement of the characteristics of.
the cell.
2
Conventionally, to obtain such a layer, a paste made of the
powdered compound semiconducterr or elements "therefor, an
eletroconducting agent, and a viscouse agnent mixed |together
was kept under reduced pressure to remove bubbIes therein
and after the deposition, the substrate was held horizontally
at about 50°C., which was lower than the drying temperature
of the viscous agent, to reduce the viscosity of the ~
viscous agent and uniformly precipitate the raw material
powders in order to obtain a high density layer. However, if
the bubbles were removed from the paste before coating, it
sometimes happened in the coating process by screen printing
that bubbles were introduced from the surrounding
'atmosphere, resulting in uneven deposition-or pin-holes.
Also, with the heat treatment only after coating, the raw
material powders did not always uniformly precipitate- and
the bubbles were not sufficiently removed, resulting in the
layer not being fat, or of uniform thickness. The pin-holes
left after coating and firing of the layers caused an Increase
of the sheet resistance. Especially, if pin-holes were formed
in the p-type CdTe layer, the carbon particles of the carbon
electrode layer formed thereon penetrated into the pin-holes
up to the CdS layer under the CdTe layer, causing internal
short circuiting or current leakage, fatally damaging the
solar cell performance.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a new
method of manufacturing compound semiconductor solar
cells comprising ntlypc and p-type compound semiconductors
and electrode layers having improved performance,
uniform characteristics, and Iow production cost. brought
about by formation of the layers without pin-holes and with
uniform thicknesses and smooth surfaces.
To obtain the above object, a method of manufacturing a
solar cell according to the present invention comprises thsteps
of forming a layer of an n-type compound semiconductor,
a layer of a p-type compound semiconductor, and an
electrode layer on a glass substrate, wherein at least one of
said steps of forming a layer of compound semiconductor
comprises preparing a paste by mixing a semiconductor raw
material and a viscous agent, applying said paste to said
substrate, drying said paste to harden it and firing said dried
paste, and vibrating said substrate during or after the application
of the paste.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic sectional view of a Group II-VI
compound semiconductor solar cell of n-CdS/p-CdTe type.
FIGS. 2(A)-2(B) are microphotographs of sections of
sintered CdS layers on a glass substrate.
FIGS. 3A-3D are graphs of the open circuit voltages.
short circuit currents, fill factors, and intrinsic photoelectric
conversion efficiencies of solar cells fabricated according to
the present invention, as well as by the conventional method.
DETAILED DESCRIPTION OF THE
INVENTION
An example of the method of manufacturing a Group
II-VI compound semiconductor solar cell according to the
present invention is now explained by referring to FIG. 1.
A paste was prepared by mixing a fine powder of cadmium
sulphide (CdS), cadmium chloride (CdCI2). and pro.
pylene glycol (PG). the CdC12 being a flux. and the PG being
a viscous agent.
U.S. Patent Jul. 23, 1996 5,538,903
Homemade Solar Cells # 401
Screen Printing
© Copyright 2003
Learn how to Screen Print. Screen printing is done
all over the world by very large printing companies
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Homemade Solar Cells # 401
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Photowatt chooses Dupont's Solamet™ materials for its PV solar
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For many years, Photowatt has been a European leader in the manufacture of
photovoltaic (PV) solar cells. Since 1997, the company, based at Bourgoin-Jallieu, near
Lyon, France, has been a part of ATS (Automation Tooling Systems), a large
multinational concern with its headquarters in Toronto, Canada. ATS specializes in the
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ATS's fully-automated solar cell lines
The company's parent, ATS, has a strong background in the automation of
manufacturing processes. This has enabled Photowatt to install two new fullyautomated
high volume PV cell and module manufacturing lines which are shown in the
photo on the right. These lines started operating in 2000 and can undertake the screen
printing of the rear and front metallisation pastes, drying and firing of the pastes,
deposition of the anti-reflective coating (ARC), sorting, ribbon soldering, lamination of
the protective insulation layer and module assembly.
Today, the standard size of a multi-crystalline Si cell is 125 x 125 mm (5 inches square)
with a thickness of 300 Mm. Using a titanium dioxide anti-reflective coating, Photowatt's
solar cell efficiency was about 13 per cent. More recently, using new silicon nitride antireflective
coating technology, this efficiency has been improved to over 15 per cent on
the company's own multi-crystalline silicon. DuPont Microclrcuit Materials has been
In 2001, the PV market grew by 39 per cent,
based on power in megawatts (MWp), and
Photowatt is well positioned to take
advantage of this buoyant market. Like most
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increased capacity every year to cope with
demand and, between 1995 and 2002, its
production capacity has increased 10-fold,
from 2 to 20 MW.
Photowatt has an advantage in the industry
by being a vertically-integrated PV cell
manufacturer with the capability to produce
solar panels from silicon feedstock. It can
therefore control all of the intermediate
processing and manufacturing steps,
including ingot casting, silicon wire sawing,
solar cell metallisation, lamination and
assembly.
Homemade Solar Cells # 401
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Homemade Solar Cells # 401
Homemade Solar Cells # 401
NOTES
Homemade Solar Cells # 401
NOTES
Homemade Solar Cells # 401
NOTES
Homemade Solar Cells # 401
NOTES
Homemade Solar Cells # 401
NOTES
Homemade Solar Cells # 401
NOTES
Homemade Solar Cells # 401
NOTES
Homemade Solar Cells # 401
NOTES
Homemade Solar Cells # 401
NOTES
Homemade Solar Cells # 401
NOTES
mSeomlaader Cells Ho
C Copyright 2003
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