U.S. patent application number 15/880288 was filed with the patent office on 2018-06-07 for method and substrates for material application.
The applicant listed for this patent is Emeka Nchekwube, Cyprian Emeka Uzoh. Invention is credited to Emeka Nchekwube, Cyprian Emeka Uzoh.
Application Number | 20180158972 15/880288 |
Document ID | / |
Family ID | 45933031 |
Filed Date | 2018-06-07 |
United States Patent
Application |
20180158972 |
Kind Code |
A1 |
Uzoh; Cyprian Emeka ; et
al. |
June 7, 2018 |
METHOD AND SUBSTRATES FOR MATERIAL APPLICATION
Abstract
A method of and an apparatus for making a composite material is
provided. The composite is able to be formed by mixing a binder and
a physical property enhancing material to form a mixer. The binder
is able to be pitch, such as mesophase pitch. The physical property
enhancing material is able to be fiber glass. The mixer is able to
be processed through a lamination process, stabilization/cross-link
process, and carbonization. The composite material is able to be
applied in the field of electronic components and green technology,
such as a substrate of a photovoltaic cell.
Inventors: |
Uzoh; Cyprian Emeka; (San
Jose, CA) ; Nchekwube; Emeka; (Morgan Hill,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Uzoh; Cyprian Emeka
Nchekwube; Emeka |
San Jose
Morgan Hill |
CA
CA |
US
US |
|
|
Family ID: |
45933031 |
Appl. No.: |
15/880288 |
Filed: |
January 25, 2018 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
13274218 |
Oct 14, 2011 |
9905713 |
|
|
15880288 |
|
|
|
|
61455060 |
Oct 15, 2010 |
|
|
|
61455061 |
Oct 15, 2010 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C04B 2235/36 20130101;
H01L 31/022425 20130101; C04B 2237/72 20130101; C04B 35/532
20130101; H01L 31/056 20141201; C04B 2235/3241 20130101; C04B
2235/72 20130101; H01L 31/03923 20130101; C04B 2237/36 20130101;
C04B 37/006 20130101; C04B 2235/522 20130101; Y02E 10/541 20130101;
Y02P 70/521 20151101; H01L 31/0322 20130101; Y02B 10/10 20130101;
C04B 35/803 20130101; C04B 2235/407 20130101; Y02E 10/52 20130101;
Y10T 29/49355 20150115; C04B 2235/425 20130101; C04B 2237/12
20130101; Y10T 29/49629 20150115; Y02P 70/50 20151101; C04B
2237/363 20130101; H01L 31/0749 20130101; C04B 2235/422 20130101;
C04B 2235/404 20130101 |
International
Class: |
H01L 31/032 20060101
H01L031/032; H02S 20/22 20140101 H02S020/22; H02S 40/22 20140101
H02S040/22; H01L 31/0224 20060101 H01L031/0224; H01L 31/0392
20060101 H01L031/0392; H01L 31/0749 20120101 H01L031/0749; H01L
31/056 20140101 H01L031/056; C04B 35/532 20060101 C04B035/532; C04B
35/80 20060101 C04B035/80; C04B 37/00 20060101 C04B037/00; H01L
31/18 20060101 H01L031/18; B32B 18/00 20060101 B32B018/00 |
Claims
1. A method of manufacturing a composite material comprising a)
selecting a first material to be added based on a selected material
property of the composite material; b) coupling the first material
with a binder material to form a mixture; and c) stabilizing or
cross-linking the binder material, such that the composite material
is formed.
2. The method of claim 1, wherein the binder material comprises
pitch, coal ash, or a combination thereof.
3. The method of claim 2, wherein the pitch comprises a mesophase
pitch.
4. The method of claim 1, wherein the selected material property
comprises conductivity or flexibility.
5. The method of claim 1, wherein the first material comprises
fiberglass.
6. The method of claim 1, further comprising forming a
laminate.
7. The method of claim 1, further comprising carbonizing the
mixture.
8. The method of claim 7, wherein the carbonizing comprises heating
the mixture in a temperature above 700.degree. C.
9. The method of claim 1, further comprising adding sulfur before
stabilizing or cross-linking the binder material.
10-17. (canceled)
18. A method of forming a composite material comprising a.
combining a fiber glass material with a binder material to form a
mixture; b. laminating the mixture to form a laminate; c.
stabilizing or cross-linking the binder material at a first
temperature; and d. carbonizing the laminate at a second
temperature.
19. The method of claim 18, wherein the binder material comprises a
pitch.
20. The method of claim 18, wherein the composite material
comprises a conducting material forming a conducting layer coupling
with a layer of material having conductivity lower than the
conductivity of the conducting layer.
21. A method of manufacturing a composite material comprising a
first conductive laminate and a second conductive laminate, the
method comprising: a) forming the first conductive laminate by a
mesophase pitch layer comprising a mesophase stabilized or
cross-linked pitch combined with a reinforcement layer comprising a
first material to be added based on a selected material property of
the composite material; and b) bonding the second conductive
laminate to the first conductive laminate by an insulative layer,
wherein the first conductive laminate, the insulative layer and the
second conductive laminate form the composite material having
alternating conductive layers, wherein the insulative layer
comprises an insulative glassy carbon binder.
22. The method of claim 21, further comprising coupling the first
material with a binder material to form a mixture.
23. The method of claim 22, further comprising stabilizing or
cross-linking the binder material, such that the composite material
is formed.
24. The method of claim 23, further comprising adding sulfur before
stabilizing or cross-linking the binder material.
25. The method of claim 22, wherein the binder material comprises
pitch, coal ash, or a combination thereof.
26. The method of claim 22, further comprising carbonizing the
mixture.
27. The method of claim 26, wherein the carbonizing comprises
heating the mixture in a temperature above 700.degree. C.
28. The method of claim 21, wherein the selected material property
comprises conductivity or flexibility.
29. The method of claim 21, wherein the first material comprises
fiberglass.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. Provisional
Patent Application Ser. No. 61/455,060, filed Oct. 15, 2010 and
entitled "NOVEL SUBSTRATES FOR MATERIALS APPLICATION," and U.S.
Provisional Patent Application Ser. No. 61/455,061, filed Oct. 15,
2010 and entitled "NOVEL SUBSTRATES FOR PHOTO VOLTAIC
APPLICATIONS," which are hereby incorporated herein by reference in
their entirety for all purposes.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of material
science. More specifically, the present invention relates to the
field of compositions for making novel materials.
BACKGROUND OF THE INVENTION
[0003] Typically, industrial wastes are unwanted and often left
unused. In recent years, the rising of the awareness of
environmental protection and energy conservation causes people to
seek ways to better use resources and reduce wastes. Methods and
strategies have been developed for waste management including waste
prevention, waste minimisation, waste reuse, waste recycling,
energy recovery, and waste disposal. Among the waste management
methods and strategies, waste reuse is one of the attractive waste
management methods, because it includes converting the unwanted
waste to other useful products. Waste reuse is described as turning
waste into gold. Thus, it is desirable to develop methods and
devices for converting and incorporating the waste into useful
products and materials.
SUMMARY OF THE INVENTION
[0004] A method of and an apparatus for making a composite material
is provided. The composite is able to be formed by mixing a binder
and a physical property enhancing material to form a mixer. The
binder is able to be pitch, such as mesophase pitch. The physical
property enhancing material is able to be fiber glass. The mixer is
able to be processed through lamination process,
stabilization/cross-link process, and carbonization. The composite
material is able to be applied in the field of electronic
components and green technology, such as a substrate of a
photovoltaic cell.
[0005] In the first aspect, a method of manufacturing a composite
material comprises selecting a first material to be added based on
a selected material property of the composite material, coupling
the first material with a binder material to form a mixture, and
stabilizing or cross-linking the binder material, such that the
composite material is formed.
[0006] In some embodiments, the binder material comprises pitch,
coal ash, or a combination thereof. In other embodiments, the pitch
comprises a mesophase pitch. In some other embodiments, the
selected material property comprises conductivity or flexibility.
In some embodiments, the first material comprises fiberglass. In
other embodiments, the method further comprises forming a laminate.
In some other embodiments, the method further comprises carbonizing
the mixture. In some embodiments, the carbonizing comprises heating
the mixture in a temperature above 700.degree. C. In other
embodiments, the method further comprises adding sulfur,
organosulfur, organometallic compounds, nanoparticles of oxides or
metals before stabilizing or cross-linking the binder material.
[0007] In the second aspect, a composite material comprises a
laminate formed by pitch and a material property enhancing
material. In some embodiments, the pitch comprises a mesophase
pitch. In other embodiments, the pitch comprises a neomesophase
pitch. In some other embodiments, the material property enhancing
material comprises fiberglass, an oxide nanoparticle, a metal
oxide, a metal nanoparticle, or a combination thereof. In some
other embodiments, the material property enhancing material
comprises conductors. In some embodiments, the conductors comprise
a metal or an alloy. In other embodiments, the material property
enhancing material comprises coal ash, milled glass, milled quartz,
glass beads, glass fiber, quartz fiber, or a combination thereof.
In some other embodiments, the material property enhancing material
comprises an insulator. In the third aspect, a method of forming a
composite material comprises combining a fiberglass material with a
binder material to form a mixture, laminating the mixture to form a
laminate, stabilizing or corss-linking the binder material at a
first temperature, and carbonizing the laminate at a second
temperature.
[0008] In some embodiments, the binder material comprises a pitch.
In other embodiments, the composite material comprises a conducting
material forming a conducting layer coupling with a layer of
material having conductivity lower than the conductivity of the
conducting layer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 illustrates a method of making a material in
accordance with some embodiments.
[0010] FIGS. 2A and 2B illustrate apparatuses for making a
substrate material in accordance with some embodiments.
[0011] FIG. 3 illustrates a photovoltaic cell in accordance with
some embodiments.
[0012] FIG. 4 illustrates a photovoltaic cell manufacturing method
in accordance with some embodiments.
[0013] FIG. 5 illustrates a mesophase pitch sheet fabrication
method in accordance with some embodiments.
[0014] FIG. 6 illustrates a mesophase pitch sheet fabrication
method in accordance with some embodiments.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0015] In some aspects of the present invention, inexpensive and/or
recycled industrial waste are used to make various materials. The
materials have wide applications in industries. For example, the
material is able to be used as part of the substrate of a
photovoltaic cell. The industrial wastes that are used herein
include pitch from the petrochemical industry and coal ash from the
coal industry and coal fired electric generating plants. The
above-mentioned waste products (such as pitch and coal ash) are
able to be used as a substrate material for flexible and
non-flexible thin film photovoltaic cells. Above listed industrial
wastes are examples that are used for illustration purposes. Other
industrial waste products are applicable.
[0016] In some other aspects of the present invention, materials
and composite structures are formed using isotropic, anisotropic
mesophase pitch, graphitizing pitch or liquid crystalline obtained
from pitch (including commercially available pitch) as a binder or
matrix material with other carbonaceous and or non-carbonaceous
materials.
[0017] In the following, methods of and apparatuses for making
materials are disclosed in accordance with some embodiments. FIG. 1
illustrates a method 100 of making the materials in accordance with
some embodiments. The method 100 is able to include adding
desired/pre-selected materials, creating a laminate with the added
materials, stabilizing and/or cross-linking a binder material, and
carbonizing. The steps of method 100 are optional. Additional steps
are able to be added to the method 100. The sequences of performing
the steps of method 100 are able to be in any order. More details
of performing method 100 are illustrated below. The method 100 is
able to begin from Step 102. At Step 104, selected
materials/components are added based on a selected material
property of the material. In some embodiments, woven fiberglass
material (silica-based and/or carbon-based material) is impregnated
with a binder material by spraying, roll-coating, dipping,
brushing, or a combination thereof. The fiberglass material
combined with the binder material forms a binder material coated
fiberglass material. A person of ordinary skill in the art
appreciates that other methods are able to be used to combine the
binder material and the added material to gain predetermined
physical interactions and properties, such as mixing, blending, and
pressing. In other embodiments, non-woven fiber glass material is
used to be combined with the binder material. The binder material
described herein is able to be pitches, coal ash, or any other
materials that are able to be used as a binder material. A person
of ordinary skill in the art appreciates that the binder material
is able to be any materials that have property of adhesion, such as
adhesives, glues, cement, and paints. The property of adhesion
includes materials that show such property under pre-defined
conditions, such as temperature, pressure, solvent, co-reactants,
or a combination thereof. For example, a binder material is within
the scope of the present invention when the binder material
demonstrates the property of adhesion under a pressure, such as 10
psi, and not adhesive under normal atmospheric pressure (e.g., 1
atm). Various other components are able to be added at Step 104
based on the pre-selected property of the products. Some of the
embodiments are discussed in the following paragraphs. At Step 106,
a laminate including the added material is created. In some
embodiments, the above formed binder material coated fiberglass
material is rolled or extruded to form a laminate. In some
embodiments, the thickness of the laminate is thinner than 20
microns. In some other embodiments, the thickness of the laminate
is thicker than 2000 microns. In some other embodiments, the
thickness of the laminate is between 20 microns and 2000 microns.
In some embodiments, the width of the laminate is in the range
between 10 cm and 1 m, such that a sheet of a laminate material is
able to be made for further cutting. In some other embodiments, the
width of the laminate is in the range between 0.5 cm and 3 cm, such
that a cell/rectangular form of a substrate is formed for
ready-to-use. A person of ordinary skill in the art would
appreciate that any width of the laminate is applicable depending
on a selected use of the substrate.
[0018] In some embodiments, the laminate includes a structure
having a mesophase pitch layer sandwiched by layers of fiber glass
on the top side and on the bottom side of the mesophase pitch
layer. For example, a sandwich structure/laminate is formed by
preparing a first layer of fiber glass sheet having a size of 1
m.sup.2 and a thickness of 3 mm, adding a second layer of a binder
material (such as a mesophase pitch) having a size of 1 m.sup.2 and
a thickness of 5 mm on top of the first layer, adding a third layer
of fiber glass sheet having a size of 1 m.sup.2 and a thickness of
2 mm, and extruding with a pressure press extruder to form a
sandwiched laminate having a thickness of 7 mm. In other
embodiments, the laminate includes a layer of fiber glass
sandwiched by two layers of pitch. In some embodiments, the pitch
is a low molecular weight neomesophase pitch or is any other
binder.
[0019] At Step 108, the binder material is stabilized or
cross-linked below the softening temperature in an oxygen ambient
to form a treated material. In some embodiments, the temperature is
in the range of 200.degree. C. to 450.degree. C. A person of
ordinary skill in the art appreciates that other temperature ranges
are applicable. In some embodiments, the temperature is near the
softening temperature. In some other embodiments, the temperature
is higher than the softening temperature.
[0020] At Step 110, the treated material is heat treated to
carbonize the mixture. In some embodiments, the temperature of Step
110 is in the range of 800.degree. C. to 1700.degree. C. In some
other embodiments, the temperature is in the range of 700.degree.
C. to 3000.degree. C. In some embodiments, the Step 110 is
performed under inert ambient, such as nitrogen, with a pressure
between 2 psi and 40 psi. In some embodiments, the pressure applied
is maintained during the cooling down step, such that shrinkage and
warpage of the sheet structure is able to be minimized. The method
100 is able to stop at Step 112.
[0021] Different material properties are selected for different
applications, such as thermal, sound, electrical, vibrational,
signal, and light conductivity/insulation, material strength, and
material durability. Various materials are able to be added in the
composite material to enhance the pre-determined property. In some
embodiments, chopped or particulate conducting materials are used
as the reinforcing agent or material, such that the conductivity of
the material produced is able to be enhanced. In some other
embodiments, chopped or particulate non-conducting materials are
used as the reinforcing agent or material, such that the property
of insulation of the material produced is enhanced. In some
embodiments, the materials that are incorporated include coal ash,
milled glass, milled quartz, glass beads, chopped glass fiber,
chopped quartz fiber mica flakes, ceramic powder/beads/flakes, and
non-carbonaceous material. In some other embodiments, the materials
that are incorporated include conducting metallic or metal alloy
powders, flakes or fibers. In some embodiments, the materials that
are incorporated include nanoparticles, such as metal nanoparticles
and metal oxide nanoparticles (e.g., Cr.sub.2O.sub.3 nanoparticles
are incorporated as a catalyst for neucleation.) A person of
ordinary skill in the art appreciates that any conducting materials
are able to be added including copper, chromium, carbon powder or
carbon flakes, graphite flakes, or combinations thereof.
[0022] In some embodiments, the electrical resistivity of the
substrate material (the material produced from the method 100) is
selected. In some embodiments, an amount of less than 5% of sulfur
or organo-sulfur compounds with or without metallic oxides or
metallic compounds is admixed into the mesophase pitch binder
before the cross-linking step such that glassy carbon is formed
during the high temperature carbonization step. Any other materials
that are able to be added to, for example, control the texture or
strength and increase or decrease the resistivity of the substrate
materials are within the scope of the present invention.
[0023] In the following, the apparatuses for making the substrate
material are disclosed. FIGS. 2A and 2B illustrate apparatuses 200
and 211 for making the substrate material in accordance with some
embodiments. The reactants, such as the fiber glass 216 and binder
materials 218, are able to be added in the mixing device 202
through the hopper 210 and 212, respectively. The reactants are
able to be in solid and/or liquid form of solvent and/or
compositions. In some embodiments, the mixing device 202 is able to
be an extruder. The mixing device 202 is able to mix the materials
added by the mixer 217, such as a screw mixer. A person of ordinary
skill in the art appreciates that any number of hoppers are able to
be included in the mixing device 202. The mixing device 202 and/or
the apparatus 200 are able to be performed under air atmosphere,
inter atmosphere (such as N.sub.2 and Ar), or pressurized
atmosphere (such as 2-10 psi and 1-3 atm).
[0024] The hoppers 210 and 212 are able to be hermetically sealed
chambers, top open chambers, hinged top opening chambers for solid
and fluids, such as gas, liquid, and supercritical fluids. The
mixing device 202 is able to include a die 214 allowing the output
material 201 to be shaped in a desired form and thickness, such as
1 mm-10 mm. In some embodiments, the apparatus 200 is able to
include a roller 204, such as a pull roller. The roller 204 is able
to use its rolling wheels and belts compressing the output material
201 to a desired thickness, such as 20 to 500 microns. The laminate
described in FIG. 1 is able to be fabricated in a batch mode or
roll-to-roll depending on the thickness of the laminate using the
mixing device 202 and/or the roller 204 described herein. The
output material 201 is able to be heated in the oven 206 in a
pre-determined temperature, such as 200.degree. C.-450.degree. C.
for stabilizing or cross-linking the binder material and
600.degree. C.-1700.degree. C. for carbonizing the materials. In
some embodiments, during the stabilization and carbonization steps,
a controlled fluid ambient is used to exact the pressure on both
major sides of the substrate. For example, the oven/furnace 206 is
able to be lined with tiny orifices 205 (with multiple heating
zones), where the gap between the upper and the lower inner furnace
walls is negligible compared to the width or length of the furnace.
In some embodiments, inert gas is introduced into the oven/furnace
206 in the carbonizing process through the tiny orifices 205 on
both side of the laminate in the oven/furnace 206 and the pressure
of the fluid is controlled to emanate on both sides of the laminate
(output material 201), such that the fluid, such as inert gas,
prevents the sheet laminate from touching the major sides of the
oven/furnace 206. In some embodiments, the gap of the fluid exit
203 of the oven 206 is reduced, such that the applied fluid is able
to be used to exact the pressure on the substrate during the
cross-linking, carbonization, or a combination thereof. In some
embodiments, the apparatus 200 is able to include one or more
cooling device 207. The output material 201 is able to be cut and
stored by a cutter 208 to a pre-determined dimension, such as 1
m.sup.2. The cutter 208 is able to be a pressure press-cut
machine.
[0025] Similar to the protrusion setup device 202, FIG. 2B shows a
pultrusion device 220. The pultrusion device 220 is able to
continuously manufacture composite materials. A fiber sheet 226 is
able to be pulled through the pitch bath 224, which is supplied by
a pitch source 222. The output material 201 in FIG. 2B is able to
be further compressed by the roller 204, heated by the over 206,
cooling down by the cooler 207, and sized by the cutter 208 similar
to the processes described in FIG. 2A and its associated texts.
Applications
[0026] The materials that are made by using the methods and
apparatuses disclosed herein in accordance with some embodiments
are able to be applied in various applications and used in various
ways. For example, in some embodiments, more than one laminate is
able to be stacked and bonded by a thin layer of mesophase pitch
binder. The orientation of the sheets is able to be parallel to
each another, cross-ply, or in any selected orientations with
respect to each other prior to the cross-linking step. The single
sheet or stacked sheets are able to be cut and formed in a suitable
mold by known methods for fabricating a pre-selected structure or
shape, such as a substrate of a solar cell.
[0027] In some embodiments, an alternatively conductive layer
structure is selected, which is able to be made by bonding the
highly conductive laminates to each other by using the more
insulative glassy carbon binder. The formed material having
alternative layers of different conductivity is able to be used as
a capacitor for low or high temperature applications. For example,
the capacitor is able to have a structure including a first layer
of highly insulating layer, a second layer of conducting layer, a
third layer of highly insulating layer, a fourth layer of
conducting layer, and a fifth layer of highly insulating layer. The
substrate made through the methods and apparatuses disclosed herein
is able to be used as flexible substrate for photovoltaic cells,
electromagnetic shielding, casing for electronic appliances and
architectural applications.
Photo Voltaic Cells
[0028] In the following, methods of making photovoltaic cells (PV)
using the material/substrate made above are provided in accordance
with embodiments.
[0029] Traditionally, sodalime glass and stainless steel sheets are
used for the fabrication of thin film solar cells. Problems are
associated with the photovoltaic cells that use sodalime glass or
stainless steel sheets as substrates. The sodalime glass substrates
are brittle, which increases the probability of defects to the
substrates and failures to the PV cells. Furthermore, the sodalime
glass substrate is rigid and not flexible, which limits its
applications to only flat surfaces.
[0030] Moreover, the sodalime glass substrate is an electrical
insulator and is expensive, which is about 40% of PV fabrication
cost. Additionally, the Tg (glass transition temperature) of
sodalime glass substrate limits the selenization temperature.
Comparing the typical PV cell with a rolled stainless steel sheet
as a substrate with the PV cell with sodalime glass as a substrate,
the rolled stainless steel sheet substrate has a more flexible and
conductive structure than the sodalime glass substrate.
Nonetheless, the rolled stainless steel sheet substrate is inferior
than the sodalime glass substrate in a way that the stainless steel
substrate has a rougher surface. Moreover, the metal contained in
the typical stainless steel substrate is able to be a source of
metallic contamination (such as Fe, Ni, and Se) to CIGS
semiconductors, because the metals contained (such as Fe, Ni, and
liquid Se) is able to diffuse through Mo grain boundaries to short
the cell. Especially, the typical selenization temperature under
inert atmosphere is between 500.degree. C. and 750.degree. C. At
such temperature, the diffusion rate of Fe and Ni becomes very fast
and the kinetics favors Fe diffusion through the open grain
boundary between Mo grains. Also, at this high temperature, molten
Se in the CIS (copper indium selenide) or CIGS (Copper indium
gallium (di)selenide: a tetrahedrally bonded semiconductor) layer
above the Mo diffuses through the Mo grain boundaries to attack the
stainless substrate beneath the Mo, shorting out the solar cells.
These defects typically result in cells with greatly reduced
efficiencies and the substrates are often scrapped. High scrap
loses and accompanying low efficiency cells produces expensive
solar cells, which are not commercially viable.
[0031] In the following, methods of making photovoltaic cells (PV)
using the material/substrate made above are provided in accordance
with embodiments.
[0032] Methods of and substances for making photovoltaic cells in
accordance with some embodiments are disclosed. In some
embodiments, the photovoltaic cells include a composite or a
non-composite carbonaceous substrate, in which isotopic or
anisotropic mesophase pitch, neomesophase pitch, or a combination
thereof is used as a binder, matrix material, or the neat material
for the fabrication of planar and non planar sheets for the
fabrication of thin film solar cells. In the following, a
photovoltaic cell having a substrate using the material disclosed
herein is provided in accordance with some embodiments.
[0033] FIG. 3 illustrates a photovoltaic cell 300 in accordance
with some embodiments. In some embodiments, the photovoltaic cell
300 includes a substrate 302, an adhesive layer 304, a Mo layer
306, an absorber layer 308, a buffer layer 310 (such as a CdS
layer), and TCO (transparent conduction oxide) layer 312. The
substrate 302 of the photovoltaic cell 300 is able to include a
mesophase/neomesophase pitch backbone substrate. In some
embodiments, the thickness of the substrate 302 is able to be 20
microns to 1 mm or more. In some other embodiments, the thickness
of the substrate 302 is able to be thicker than 5 mm. A person of
ordinary skill in the art appreciates that any thickness of the
substrate 302 is applicable. The physical and material properties
of the substrate 302 is adjustable by adding pre-selected fillers
based on the applications. The rigidity/flexibility, conductivity,
the degree of thermal expansion, and surface roughness for the
substrate 302 are all adjustable and controllable. For example, a
conductive substrate 302 is able to be made by adding conductive
materials, catalysts, nanoparticles, and metallic oxides (e.g., a
filler) to the binder material during the manufacturing process.
When an insulating substrate 302 is desired, the insulating
substrate is able to be made by adding insulating materials to the
binder material during the manufacturing process. Similarly, a
flexible substrate 302 is able to be made by adjusting the hardness
or stiffness of the binder materials or the types of materials to
be added. The substrate 302 made using the methods and materials
disclosed herein is able to withstand a higher selenization
temperature range than the substrate made by typical methods. Since
the substrate 302 made using the methods and materials disclosed
herein has minimal to no undesirable metallic impurities, short of
the cell is able to be avoided when heating the photovoltaic cell
under a high temperature.
[0034] In some embodiments, the photovoltaic cell 300 includes an
adhesive layer 304. The adhesive layer 304 is able to be a Cr layer
and applied on top of the substrate 302 by sputtering and other
known methods. The thickness of the adhesive layer 304 is able be
between 20 nm to 1000 nm. A person of ordinary skill in the art
appreciates that any thickness of the adhesive layer 304 is
applicable, such as 2 mm or thicker.
[0035] In some embodiments, the photovoltaic cell 300 includes a Mo
layer 306. The Mo layer 306 is able to be on top of the adhesive
layer 304. The Mo layer 306 is able to serve as the back contact
and to reflect most unabsorbed light back into the absorber layer
308 (such as a CIGS layer). The Mo layer 306 is able to be a thin
film deposited by PVD (physical vapor deposition) such as
sputtering and evaporation and other known methods, such as CVD
(chemical vapor deposition). The thickness of the Mo layer 306 is
able to be between 100 nm to 2000 nm. A person of ordinary skill in
the art appreciates that any thickness of the Mo layer 306 is
applicable, such as 2 microns or thicker. In some embodiments,
multiple Mo layers 306 are able to be included to attain a
pre-defined Mo film thickness. In some embodiments, a thin layer Mo
alloy (such as a 2 nm to 10 nm MoSi layer) is inserted within the
Mo laminate to modify the grain structure of the Mo film coated
over the alloy layer.
[0036] In some embodiments, the photovoltaic cell 300 includes an
absorber layer 308, such as CIGS layer or a CIG/CIS layer. The
absorber layer 308 is able to be formed by
depositing/sputtering/evaporating precursor materials/layers, such
as Cu, In, Ga, or a combination thereof on the Mo layer 306
followed by selenization. The absorber is able to be formed using
typical methods of forming CIGS layers. In some embodiments, the
precursor materials/layers are able to be coated with a thin layer
of sodium fluoride prior to the selenization step in inert ambient
between the temperature of 500.degree. C. and 800.degree. C. for 5
minutes to 120 minutes in excess selenium ambient, such as
H.sub.2Se or Se.sub.(g).
[0037] In some embodiments, the photovoltaic cell 300 includes a
buffer layer 310. The buffer layer 310 is able to be n-type CdS.
The buffer layer is able to be coated on the absorber layer 308 by
typical methods. In some embodiments, the photovoltaic cell 300
includes a transparent conducting oxide layer (TCO) 312. The TCO
layer 312 is able to be doped with Al. The TCO layer is able to
collect and move electrons out of the cell while absorbing as
little light as possible. In some embodiments, the photovoltaic
cell 300 includes electrical wiring elements 314 on the TCO layer
312 for conducting electronic signals and electricity. In some
embodiments, the photovoltaic cell 300 is able to be laminated with
polymer films to form flexible solar cells.
[0038] FIG. 4 illustrates a photovoltaic cell manufacturing method
400 in accordance with some embodiments. The method 400 is able to
begin from Step 402. At Step 404, an adhesive layer is coated on a
substrate. The substrate is able to be manufactured using the
method described above. In some embodiments, the adhesive layer
contains Cr or a Cr sheet/layer. In some embodiments, the substrate
is a mesophase matrix substrate. The mesophase matrix substrate is
able to be a bottom electrode of the photovoltaic cell. In some
other embodiments, the substrate is a composite carbonaceous
substrate. In other embodiments, the substrate is a non-composite
carbonaceous substrate. The substrate is able to be isotropic or
anisotropic mesophase pitch, neomesophase pitch, or a combination
thereof. A person of ordinary skill in the art appreciates that
other materials that are adhesive or adhesive under predetermined
conditions are applicable. At Step 406, a Mo layer is coated on the
adhesive layer, which is able to couple the substrate with an
absorber layer. At Step 408, precursor materials, such as Cu, In,
Ga, and Se (Copper indium gallium selenide), are coated on the Mo
layer. At Step 410, selenization is performed. In the process of
selenization, Se is able to be supplied in the gas phase (for
example as H.sub.2Se or elemental Se) at high temperatures, and the
Se becomes incorporated into the film by absorption and subsequent
diffusion. By performing the selenization, an absorber of the
photovoltaic cell is able to be formed. At Step 412, CdS layer
formation on the absorber (CIGS) layer is performed. At Step 414, a
layer of TCO is coated on the CdS layer. At Step 416, wiring
elements are fabricated on the TCO. The method 400 is able to stop
at Step 418. In the following, a method of forming the mesophase
pitch sheet that is able to be used as the substrate in the method
400 described above is provided.
[0039] FIG. 5 illustrates a mesophase pitch sheet fabrication
method 500 in accordance with some embodiments. The method 500
begins from Step 502. At Step 504, a pitch is added. The pitch is
able to be graphitizable isotropic carbonaceous pitch from Ashland
240 or 260 (petroleum pitch) from coal. A person of ordinary skill
in the art appreciates that the pitch is able to be from various
sources, such as directly from industrial waste. At Step 506,
solvent extraction and heat treatment is performed with the pitch.
At Step 508, mesophase or neomesophase materials are formed. In
some embodiments, the mesophase or neomesophase materials contain
liquid crystals more than 50% of the composition. At Step 510, the
mesophase or neomesophase materials are dried and communition is
performed. At Step 512, sheet extrusion is performed under inter
ambient atmosphere at 250.degree. C. to 300.degree. C. At Step 514,
sheet stabilization is perform by heating the sheet at 250.degree.
C. to 300.degree. C. At Step 516, high temperature treatment is
performed at inert ambient at 600.degree. C. to 3000.degree. C. The
method 500 is able to stop at Step 518. In the following, a method
of incorporating filler materials into the substrate
material/mesophase sheet material is provided.
[0040] FIG. 6 illustrates a mesophase pitch sheet fabrication
method 600 in accordance with some embodiments. The method 600
begins from Step 602. At Step 604, a pitch is added. The pitch is
able to be graphitizable isotropic carbonaceous pitch from Ashland
240 or 260 (petroleum pitch) from coal. A person of ordinary skill
in the art appreciates that the pitch is able to be from various
sources, such as directly from industrial waste. At Step 606,
solvent extraction and heat treatment is performed. At Step 608,
mesophase or neomesophase materials are formed.
[0041] In some embodiments, the mesophase or neomesophase materials
contain liquid crystals more than 50% of the composition. At Step
610, the mesophase or neomesophase materials are dried and
communition is performed. At Step 611, filler material is added.
The filler to be added is able to be chosen based on the
pre-selected physical/chemical property of the substrate (product).
At Step 612, sheet extrusion is performed under inter ambient
atmosphere at 250.degree. C. to 300.degree. C. At Step 614, sheet
stabilization is performed by heating the sheet at 250.degree. C.
to 300.degree. C. At Step 616, low melting point and/or low
molecular weight mesophase pitch is formed, which is able to be
used to laminate multiple sheet material. The method 600 is able to
stop at Step 618.
[0042] All steps described above are optional. The sequence of
performing the steps that are included in the methods above is able
to be in any order. Additional steps are able to be added.
[0043] The present application is able to be utilized in making
various materials for industrial applications, such as the
substrate of a solar cell. In operation, a photovoltaic solar cell
with a flexible substrate made with the methods provided herein is
able to be bent to a desired shape and applies on a non-flat
surface.
[0044] The term pitch used herein is able to include tar,
asphaltene, viscoelastic polymers, asphalt, bitumen, carbon
disulfide, and resin. In some embodiments, the high viscosity of
the chosen binder (such as pitch) or the added material provides a
function to retain the metallic particles in the substrate and
prevent them from shorting the PV cell. In some embodiments, the
materials/substrates made using the methods and compositions
disclosed herein is able to be used as a heat insulation device,
like thermal paint, which is able to be installed on/apply on or as
a part of the roof or wall of a building structure, such as a house
or a barn. In some embodiments, the materials/substrates comprise
conductive material having high electrical conductivity, so the
materials/substrates are able to be used to conduct electricity. In
some other embodiments, the materials/substrates have high
reflectivity of heat and/or lights, and the substrates and the
materials are able to be used as mirrors on building structures.
The mirrors described herein are able to reflect/insulate/isolate
heat, lights, or a combination thereof. In some embodiments, the
substrates/materials are able to reflect more than 90% of the
incoming lights or selected wavelengths of lights, such as IR and
UV.
[0045] The present invention has been described in terms of
specific embodiments incorporating details to facilitate the
understanding of principles of construction and operation of the
invention. Such reference herein to specific embodiments and
details thereof is not intended to limit the scope of the claims
appended hereto. It will be readily apparent to one skilled in the
art that other various modifications may be made in the embodiment
chosen for illustration without departing from the spirit and scope
of the invention as defined by the claims.
* * * * *