Researchers at the Fraunhofer Institute for Polymer Applications in Germany are pioneering a groundbreaking innovation: ultra-thin glass embedded with organic solar cell modules. This new material combines the durability of glass with the flexibility needed for advanced photovoltaic applications. Glass, known for its excellent sealing properties, can endure high temperatures up to 400°C, making it an ideal choice for manufacturing processes.
Organic photovoltaic (OPV) modules offer a promising alternative to traditional silicon-based solar cells. Unlike conventional methods, OPVs can be produced under atmospheric pressure and are compatible with printing technologies, which significantly speeds up the production process and reduces costs. A key requirement for this technique is a flexible substrate, and that's where Corning comes in. The company has developed a specialized type of glass that can be as thin as 100 microns—roughly the thickness of a sheet of paper—making it highly suitable for use in these cutting-edge solar cells.
The collaboration between scientists and Corning has already led to the successful creation of the first organic solar cell module using a "chip-to-film" approach. Following this, they tested a more scalable "roll-to-roll" method, similar to how newspapers are printed. In this process, the carrier substrate is fed from one roll to another, with the active layer and electrodes being printed in between through multiple passes. For the first time, the team managed to produce a uniform layer on a smaller substrate, marking a significant step forward.
Now, researchers are fine-tuning the process to make it suitable for large-scale industrial production. The long-term vision is to create high-strength, high-performance organic solar modules tailored for various applications—from small-scale uses like powering mobile devices to large solar farms. This technology could revolutionize the way we harness solar energy, offering greater flexibility, efficiency, and sustainability.
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