Solar cells integration in over-molded printed electronics

The continuous drive to have smart flexible systems in different application areas as automotive, households, and consumer electronics utilize the development of different integration approaches to include many electronic functionalities in 3D structures. This article reports a new conceptual idea that may be used as a platform for the integration of photovoltaic (PV) cells in plastic products. By using over-molding techniques, a thin flexible power source can be produced using amorphous silicon photovoltaic modules integrated into a thermoplastic material. Moreover, a clear benefit is achieved from such a combination of solar cells applied on flexible printed foils and the use of injection molding manufacturing process. The advantages include: being lightweight, flexibility as well as cost-effectiveness. The fabrication process is explained on both single and a matrix of PV modules. Different materials used for adhesion between the cells and the printed foils are discussed in this article. Each integrated sample consisted of a flexible substrate with a PV module assembled and fixed as an insert in the mold of the injection molding machine. A polymer is over-molded on it and a plastic part is formed. Afterwards, the solar cells are tested using IV measurements to confirm the feasibility of the technology to act as a thin light power source for different applications.