Parallel, portable
dye-sensitized solar cell modules with 5 ×
5 cm2 of area containing either a polymer gel electrolyte
or a standard liquid electrolyte were assembled and characterized
as a function of time. For modules sealed with the thermoplastic Surlyn,
a rapid loss of performance was observed, due to an insufficient protection
of the metallic current collectors (silver grids) of the module and,
sometimes, also associated with electrolyte leakage. Similar results
were obtained using a glass frit layer as the only material for protective
overcoat of the silver grids. Thus, the combination of the Surlyn
with a glass frit was investigated. The process based on the combination
of two materials allowed achieving a more effective sealing, with
enhanced process yield and sample reproducibility. The modules assembled
by this method, filled with either a polymer gel electrolyte or liquid
electrolyte, showed an enhanced stability. Concomitantly, the formulation
of the polymer gel electrolyte was also addressed and had to be tuned
to allow an easier filling of the modules.