In this paper, we report on the outcome of a German network project conducted with 12 partners from universities and research institutes on the material development of dye solar cells (DSC). We give an overview in the field and evaluate the concept of monolithic DSC further with respect to upscaling and producibility on glass substrates. We have developed a manufacturing process for monolithic DSC modules which is entirely based on screen printing. Similar to our previous experience gained in the sealing of standard DSC, the encapsulation of the modules is achieved in a fusing step by soldering of glass frit layers. For use in monolithic DSC, a platinum free, conductive counter electrode layer, showing a charge transfer resistance of R CT < 1Á5 V cm 2 , has been realized by firing a graphite/carbon black composite under an inert atmosphere. Glass frit sealed monolithic test cells have been prepared using this platinum-free material. A solar efficiency of 6% on a 2Á0 cm 2 active cell area has been achieved in this case. Various types of non-volatile imidazolium-based binary ionic liquid electrolytes have been synthesized and optimized with respect to diffusion-limited currents and charge transfer resistances in DSC. In addition, quasi-solid-state electrolytes have been successfully tested by applying inorganic (SiO 2 ) physical gelators. For the use in semi-transparent DSC modules, a polyol process has been developed which resulted in the preparation of screen printed, transparent catalytic platinum layers showing an extremely low charge transfer resistance (0Á25 V cm 2 ).
A cost effective glass soldering technique was developed which has been successfully applied to the dye solar cell (DSC) technology. A complete manufacturing process of DSC modules -ranging from screen-printed layers to semi-automated colouring and electrolyte filling -in a laboratory-scale baseline has been accomplished. The manufacturing process of 30 x 30 cm² modules was partly transferred to large areas of 60 x 100 cm². Electrolytes based on non-volatile organic ionic liquids have been tested as good candidates for long-term stability and performance. By screen printing a light scattering ZrO2 layer over the transparent active area of the module, various different patterns -ranging from logo-type to image-type designs -were realised. Additionally, the leadfree glass frit was coloured by inorganic pigments to adjust the unique esthetical appearance of the module.
KurzfassungAluminiumschäume stehen an der Schwelle industrieller Anwendungen. Viele neue Einsatzgebiete können für diese neuen Werkstoffe gefunden werden, wenn sich eine definierte, verschleiß- und korrosionsbeständige Oberfläche einstellen lässt. Dies ist sehr gut mit den Verfahren des thermischen Spritzens möglich. Die metallographische Beurteilung dieser Verbunde ist sehr anspruchsvoll, da die teils sehr harten Schichten gänzlich andere Eigenschaften aufweisen als der sehr weiche und großporige Aluminiumschaum. Im folgenden Artikel werden die Aluminiumschäume sowie die zur Veredelung verwendete Spritztechnik kurz vorgestellt; den Schwerpunkt bilden eine angepasste metallographische Präparation sowie Probleme, die hierbei auftreten können.
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