Tiny grooves reshape the future of solar cell manufacturing
Flexible solar cells that do not rely on rare earth metals are paving the way for low-cost, highly efficient solar energy, according to new research from the University of Sheffield. This breakthrough, developed in collaboration with UK-based company Power Roll Ltd, has been published in ACS Applied Energy Materials and presents a transformative approach to solar energy production.
The researchers have created a new type of solar cell using a perovskite semiconductor, which differs significantly from conventional solar panels. By embossing tiny grooves into a plastic film and filling them with perovskite material, they have developed lightweight, flexible solar films. These innovative films can be applied to surfaces such as rooftops and other unconventional areas where traditional solar panels would be too heavy. Their affordability and versatility could accelerate the adoption of solar energy, particularly in developing nations, aiding the global transition from fossil fuels to sustainable energy sources.
A key feature of this new solar cell is its microgroove structure, which results in a back-contact format. Unlike conventional solar cells that use a layered sandwich structure, back-contact cells consolidate all electrical connections on the reverse side. This design simplifies manufacturing, reduces costs, and enhances efficiency.
To analyse the structure and composition of these solar cells, the researchers employed a Hard X-ray nanoprobe microscope at diamond light source in oxfordshire. This cutting-edge imaging technique allowed them to detect hidden defects, such as voids and boundary irregularities within the semiconductor material. Notably, this was the first instance of such an analysis being used for this type of solar cell.
Another major advantage of this technology is its avoidance of rare and costly materials like indium, making it a scalable and sustainable alternative. Professor David Lidzey, from the School of Mathematical and Physical Sciences at the University of Sheffield and co-author of the paper, emphasised the potential impact of this development:
“A key advantage of these flexible films is that they can be adhered to virtually any surface. In the UK, the structural integrity of many warehouse roofs means they are unsuitable for conventional solar panels due to their weight. With this lightweight solar technology, panels can be affixed almost anywhere, representing a game-changer for solar energy, especially in low and middle-income countries.”
Professor Lidzey highlighted the strategic importance of solar energy research at the University of Sheffield, noting that the institution has been at the forefront of innovative techniques for fabricating and depositing solution-processable solar cells. The decade-long collaboration with Power Roll has yielded significant advancements, culminating in this breakthrough.
The University of Sheffield has established itself as a global leader in sustainability and advanced manufacturing. Its commitment to tackling energy challenges and promoting renewable energy aligns seamlessly with Power Roll’s mission to create secure, deployable clean energy solutions. The two partners have previously collaborated on multiple projects, reinforcing the UK’s position as a hub for clean energy innovation.
Dr Nathan Hill, Research Scientist at power roll and lead author of the study, underscored the significance of the partnership:
“This collaboration highlights how cutting-edge academic research and industrial innovation can merge to drive transformative renewable energy solutions. We are advancing a technology that could play a pivotal role in achieving global net-zero targets. By pooling our research and academic expertise, we continue to validate the science underpinning Power Roll’s technology.”
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Dr Hill also noted that Power Roll had previously worked with the University’s Department of Physics and Astronomy to refine solar designs that lowered manufacturing costs while improving efficiency. With perovskite solar energy still in its infancy, continued research and academic involvement are essential for accelerating product development and deepening scientific understanding.
The next phase of this project will involve further exploration of X-ray microscopy for material characterisation. New experiments are scheduled for the summer at Diamond Light Source to investigate key aspects of device stability and performance.
Dr Jessica Walker, I14 beamline scientist at Diamond Light Source Ltd, commented:
“The techniques and resolution offered by I14 are ideally suited to answering the remaining scientific questions surrounding perovskite-based solar cell materials. It is exciting to see how our capabilities have supported both academic and industrial research, culminating in a promising advancement in energy materials with high-impact potential.”
As global efforts to transition to renewable energy intensify, this research represents a crucial step forward in making solar power more accessible, affordable, and efficient. The breakthrough achieved by the University of Sheffield and Power Roll may well redefine how solar energy is deployed across the world, driving a cleaner and more sustainable future.
