本實驗挑戰製造一個 30 × 60 cm 的大型染料敏化太陽能電池。染料敏化太陽能是一種易於製造且具製造成本相對低的光伏裝置。本實驗所使用的化學試劑主要來自 Greatcell Solar，成本約為每平方公分0.7美金。然而，此DIY版本的轉換率仍相對低，遠不及商業標準，這主要受限於系統內 FTO 或 ITO 層的高方阻、surlyn film封裝的缺席以及電解液注入的不完全。
本實驗原型由12個子電池構成，並以 Z 型串聯組態構成，每個子電池尺寸為3x28cm，間距為2公分。每個次電池為並在對電極上印刷銀電極線，銀線寬度約為5mm，測得開放電壓5.8V 和短路電流 53mA。
一項主要的發現是以玻璃窯450ºC燒結的大型玻璃具有熱變形現象，這造成了注入電解液的困難。電解液注入得助於兩片平整玻璃間毛細作用的幫助，任何輕微的變形都會破壞毛細作用的維持。升溫速度約為每分鐘8ºC，到達450ºC後持溫30分鐘，再於窯內自然降溫到室溫。
This experiment challenges the fabrication of a large-scale dye-sensitized solar cell (DSSC) with dimensions of 30 × 60 cm. DSSCs are a type of photovoltaic device known for their relatively low-cost and accessible fabrication process. The chemical reagents used in this experiment were mainly sourced from Greatcell Solar, with a material cost of about 0.7 USD per cm².
However, the conversion efficiency of this DIY version remains relatively low and falls short of commercial standards. The main limitations arise from the high sheet resistance of the FTO/ITO layer, the absence of Surlyn film sealing, and the incomplete injection of electrolyte.
The prototype consists of 12 sub-cells connected in a Z-shaped series configuration. Each sub-cell measures 3 × 28 cm with a 2 cm spacing. On the counter electrode, silver electrode lines (approx. 5 mm wide) were screen-printed. The device demonstrated an open-circuit voltage of 5.8 V and a short-circuit current of 53 mA.
One key finding is that large glass substrates sintered at 450 °C in a glass kiln showed noticeable thermal deformation, which created difficulties during electrolyte injection. Electrolyte filling typically relies on capillary action between two flat glass plates, and even slight warping disrupts this mechanism.
The thermal profile followed a ramp-up rate of about 8 °C per minute to 450 °C, held for 30 minutes, and then cooled naturally in the kiln back to room temperature.
