A simple dye-sensitized solar cell sealing technique using a CO2 laser beam excited by 60 Hz AC discharges

Dye-sensitized solar cells (DSSCs) use two glass substrates (photo electrode and counter electrode) coated with fluorine-doped tin oxide (FTO) to harvest light into the cell and to collect electrons. The space between the photo electrode and the counter electrode are filled with a liquid type electrolyte for electron transfer into the cell. Therefore, an appropriate sealing method is required to prevent the liquid electrolyte leaking out. In this paper, a simple CO2 laser beam with TEM00 mode excited by a 60 Hz AC discharge was used to seal two glass substrates coated with FTO for the fabrication of DSSCs. The sealing technique improved the durability and stability of the DSSCs. The optimal conditions for the sealing of the DSSCs are related to the pin-hole diameter, the discharge current and the moving velocity of the target. Especially, the CO2 laser beam is used as a heat source that is precisely controlled by the pin-hole, which plays an important role in adjusting its spot size. From these results, the maximum laser power was found to be 40 W at 18 Torr and 35 mA. In order to achieve the best sealing quality, the following parameters are required: a pin-hole diameter of 4 mm, input voltage of 10.73 kV, discharge current of 9.31 mA, moving velocity of 1 mm/s and distance from the target surface of 26.5 cm. Scanning electron microscope images show that the sealing quality obtained using the CO2 laser beam is superior to that obtained using a hot press or soldering iron.