Search

Abstract: The polymer and organic solar cell technology is critically presented in the context of other thin film technologies with a specific focus on what it will take to make them a commercial success. The academic success of polymer and organic solar cells far outweigh any other solar cell technology when judging by the number of scientific publications whereas the application of polymer and organic solar cells in real products is completely lacking. This aspect is viewed as a sign of the polymer and organic solar cell field as being more complex and less mature and it raises the question of whether an organic analog to a successful inorganic technology is forcibly needed and indeed whether it is at all worth exploring beyond academia. [Copyright &y& Elsevier]

Abstract: The performance of printable metal back electrodes for polymer solar cells were investigated using light beam induced current (LBIC) mapping of the final solar cell device after preparation to identify the causes of poor performance. Three different types of silver based printable metal inks were employed. Organic solvent based, UV-curable and water based silver inks were tested. Both grid electrodes and full electrodes were employed and it was shown via the grid electrode that the organic solvent based ink adversely affects the device performance under the printed metal whereas both the UV-curable and the water based inks were neutral to improving device performance. Complete roll-to-roll (R2R) processed modules were also tested and some limitations of the LBIC technique was identified for serially connected modules. [Copyright &y& Elsevier]

Abstract: A round robin for the performance of roll-to-roll coated flexible large-area polymer solar-cell modules involving 18 different laboratories in Northern America, Europe and Middle East is presented. The study involved the performance measurement of the devices at one location (Risø DTU) followed by transportation to a participating laboratory for performance measurement and return to the starting location (Risø DTU) for re-measurement of the performance. It was found possible to package polymer solar-cell modules using a flexible plastic barrier material in such a manner that degradation of the devices played a relatively small role in the experiment that has taken place over 4 months. The method of transportation followed both air-mail and surface-mail paths. [Copyright &y& Elsevier]

Abstract: A roll-to-roll process for polymer solar cells that does not involve indium-tin-oxide (ITO) is presented. A commercially available kapton foil with an overlayer of copper was used as the substrate. Sputtering of titanium metal onto the kapton/copper in an R2R vacuum process gave the monolithic substrate and back electrode for the devices. The active layer was slot-die coated onto the kapton/Cu/Ti foil followed by slot-die coating of a layer of PEDOT:PSS. No patterning of the first four layers was necessary and only the final front electrode required a pattern. The front electrode was applied by screen printing a protective layer in the areas for front electrode contacts and finally a silver grid was applied by screen printing. The topology of the device and the choice of final grid electrode geometry allowed for serial connection of the individual cells into modules. The individual cells were as large as 150×150mm. The geometric fill factors were as high as 74% and thus much higher than is readily achieved using serially connected cells on the same substrate. [Copyright &y& Elsevier]

Abstract: Pad printing as a technique for preparing the active layer in polymer solar cells is presented. The technique employs a silicone rubber stamp to pick up the motif from a gravure plate and transfer it to the substrate. The strengths and limitations of pad printing are discussed and polymer solar cells prepared by pad printing are presented. Devices were prepared on indium tin oxide substrates but in principle the entire photovoltaic device comprising front and back electrodes, barrier layers and active layer could be printed with no need for vacuum steps. The device geometry comprises a spin coated transparent zinc oxide front electrode, a pad printed active layer based on a bulk heterojunction of the thermocleavable polymer poly(3-(2-methylhexyloxycarbonyl)thiophene-co-thiopene) (P3MHOCT) and zinc oxide nanoparticles, spin coated PEDOT:PSS and finally a manually cast thermally cured silver paste back electrode. The P3MHOCT was converted to poly(3-carboxy-dithiophene) (P3CT) in situ by heating the film to for a brief period. The entire printing and device preparation was carried out in the ambient atmosphere and the devices obtained had a good stability in air during storage and operation. [Copyright &y& Elsevier]

Abstract: A complete polymer solar cell module prepared in the ambient atmosphere using all-solution processing with no vacuum steps and full roll-to-roll (R2R) processing is presented. The modules comprise five layers that were prepared on a 175-μm flexible polyethyleneterephthalate (PET) substrate with an 80-nm layer of transparent conducting indium–tin oxide (ITO). The ITO layer was first patterned by screen printing an etch resist followed by etching. The second layer was applied by either knife-over-edge (KOE) coating or slot-die coating a solution of zinc oxide nanoparticles (ZnO-nps) followed by curing. The second layer comprised a mixture of the thermocleavable poly-(3-(2-methylhexan-2-yl)-oxy-carbonyldithiophene) (P3MHOCT) and ZnO-nps and was applied by a modified slot-die coating procedure, enabling slow coating speeds with low viscosity and low surface tension ink solutions. The third layer was patterned into stripes and juxtaposed with the ITO layer. The fourth layer comprised screen-printed or slot-die-coated PEDOT:PSS and the fifth and the final layer comprised a screen-printed or slot-die-coated silver electrode. The final module dimensions were 28cm×32cm and presented four individual solar cell modules: a single-stripe cell, a two-stripe serially connected module, a three-stripe serially connected module and finally an eight-stripe serially connected module. The length of the individual stripes was 25cm and the width was 0.9cm. With overlaps of the individual layers this gave a width of the active layer of 0.6cm and an active area for each stripe of 15cm2. The performance was increased ten fold compared to mass-produced modules employing screen printing for all five layers of the device. The processing speeds employed for the R2R processed layers were in the range of 40–50mh−1. Finally a comparison is made with the state of the art represented by P3HT–PCBM as the active layer and full R2R solution processing using slot-die coating. [Copyright &y& Elsevier]

Abstract: A complete polymer solar cell module prepared in the ambient atmosphere under industrial conditions is presented. The versatility of the polymer solar cell technology is demonstrated through the use of abstract forms for the active area, a flexible substrate, processing entirely from solution, complete processing in air using commonly available screen printing, and finally, simple mechanical encapsulation using a flexible packaging material and electrical contacting post-production using crimped contacts. We detail the production of more than 2000 modules in one production run and show that the production technique is scalable and well suited for direct transfer to the printing industry employing existing production equipment. The production speed and cost analysis for the individual modules from this batch is discussed and a forecast for the high volume cost based on this method is given. Further, the points where significant cost reductions can be achieved are identified. The use of the solar cell as the power supply for a small radio and other small electronic circuits is demonstrated. Lastly, the operational stability under ambient conditions in the dark and under illumination is discussed. [Copyright &y& Elsevier]

Abstract: Polymer solar cells are reviewed in the context of the processing techniques leading to complete devices. A distinction is made between the film-forming techniques that are used currently such as spincoating, doctor blading and casting and the, from a processing point of view, more desirable film-forming techniques such as slot-die coating, gravure coating, knife-over-edge coating, off-set coating, spray coating and printing techniques such as ink jet printing, pad printing and screen printing. The former are used almost exclusively and are not suited for high-volume production whereas the latter are highly suited, but little explored in the context of polymer solar cells. A further distinction is made between printing and coating when a film is formed. The entire process leading to polymer solar cells is broken down into the individual steps and the available techniques and materials for each step are described with focus on the particular advantages and disadvantages associated with each case. [Copyright &y& Elsevier]

Abstract: A polymer solar cell that can be stored under ambient conditions (25°C and 35±5% relative humidity) in the dark for 6 months without noticeable degradation in performance is presented. The active layer is based on low-cost materials and is free from fullerenes. No vacuum steps are required for processing the device that employs an inverted device geometry, where the active layers in the device comprise a transparent cathode based on solution processed zinc oxide, an active layer based on a bulk heterojunction of zinc oxide nanoparticles and poly-(3-carboxydithiophene) (P3CT), a PEDOT:PSS layer and finally a printed silver based anode. No encapsulation was employed and the devices were robust and not sensitive to mechanical handling of the active layer and back electrode. The accelerated lifetime in air defined as 80% of the initial performance at continuous illumination (1000Wm−2, AM1.5G, 72±2°C, ambient atmosphere, 35±5% humidity) was typically 100h and the devices were tested for 150h. When keeping the same conditions and lowering the temperature, stable operation for hundreds of hours was possible. In terms of long-term stability, this performance is inferior to inorganic photovoltaics but the technology compares well and competes with small batteries in terms of capacity. The device efficiency more than doubled upon decreasing the incident light intensity from 1000 to 100Wm−2. [Copyright &y& Elsevier]

Abstract: The incorporation of polymer photovoltaics into textiles was demonstrated following two different strategies. Simple incorporation of a polyethyleneterphthalate (PET) substrate carrying the polymer photovoltaic device prepared by a doctor blade technique necessitated the use of the photovoltaic device as a structural element. The total area of the device on PET was typically much smaller than the active area due to the decorative design of the aluminium electrode. Elaborate integration of the photovoltaic device into the textile material involved the lamination of a polyethylene (PE) film onto a suitably transparent textile material that was used as substrate. Plasma treatment of the PE-surface allowed the application of a PEDOT electrode that exhibited good adherence. Screen printing of a designed pattern of poly 1,4-(2-methoxy-5-(2-ethylhexyloxy))phenylenevinylene (MEH-PPV) from chlorobenzene solution and final evaporation of an aluminium electrode completed the device. The total area of the textile device was 1000cm2 (25cm×40cm) while the active area (190cm2) was considerably smaller due to the decorative choice of the active material. [Copyright &y& Elsevier]

Abstract: The synthesis of a zwitterionic ruthenium dye that binds to anatase surfaces and has a built-in functionality that allows for the attachment of a conjugated polymer chain is presented. The system was found to adsorb on the surface of anatase anchored by the ruthenium dye. Two types of devices were prepared: standard photoelectrochemical (PEC) solar cells and polymer solar cells. The PEC solar cells employed a sandwich geometry between TiO2 nanoporous photoanodes and Pt counter electrodes using LiI/I2 in CH3CN as an electrolyte. The polymer solar cells employed planar anatase electrodes and the complex was adsorbed onto the surface before evaporation of gold electrodes. Alternative devices were obtained by spincoating of the polymer solution onto PEDOT:PSS covered indium-doped tin oxide substrates. PEC solar cells gave the best results and the main finding was that the polymer chain served as a light harvesting antenna for the ruthenium dye. [Copyright &y& Elsevier]

Abstract: The interlayer adhesion of roll-to-roll processed flexible inverted P3HT:PCBM bulk heterojunction (BHJ) polymer solar cells is reported. Poor adhesion between adjacent layers may result in loss of device performance from delamination driven by the thermomechanical stresses in the device. We demonstrate how a thin-film adhesion technique can be applied to flexible organic solar cells to obtain quantitative adhesion values. For the P3HT:PCBM-based BHJ polymer solar cells, the interface of the BHJ with the conductive polymer layer PEDOT:PSS was found to be the weakest. The adhesion fracture energy varied from 1.6J/m2 to 0.1J/m2 depending on the composition of the P3HT:PCBM layer. Post-deposition annealing time and temperature were shown to increase the adhesion at this interface. Additionally the PEDOT:PSS cells are compared with V2O5 cells whereby adhesive failure marked by high fracture energies was observed. [Copyright &y& Elsevier]

Patterns for fully printed polymer solar cells are presented that inherently enable scaling of the power output with single point electrical energy connection is presented. Connection is made to only one end of the printed foil that can be rolled out for light energy harvesting. The power level is simply increased/decreased by increasing/decreasing the length of the foil with a corresponding increase/decrease in operating voltage. The current flow runs in both directions along the printed foil thus alleviating the need for post process addition of complex busbar topologies. The power conversion takes place in a HVDC–DC converter that is tailored specifically for operation with polymer solar cells by regulation on the input side. The system charges a lithium-polymer battery thus enabling storage of 82 Wh for a printed OPV foil measuring 0.305 m×9 m having a nominal power output of at least 15 W (AM1.5G, 1000 W m −2 ). As a demonstration we present a scalable fully integrated and compact power unit for mobile applications comprising solar energy harvesting OPV modules, power conversion and storage. Applications possible include electrical charging of mobile devices, illumination using LED lamps and low mechanical power applications such as pumping water. [ABSTRACT FROM AUTHOR]

We report manufacture of fully printed and coated polymer solar cells on a small scale roll-to-roll coater representing the intermediate scale between laboratory and pilot scale. We highlight the enormous span in scale between the laboratory scale and the intended industrial scale by a factor of >100.000 and detail how this enormous scale must be covered by equipment that follow the scale. Especially the intermediate scale between equipment that can fit inside a fume cupboard and the typical pilot equipment with a footprint having the size of a large room presents a challenge that comprises some of the most critical steps in the scaling process. We describe the development of such a machine that comprise web guiding, tension control and surface treatment in a compact desk size that is easily moved around and also detail the development of a small cassette based flexographic unit for back electrode printing that is parsimonious in terms of ink usage and more gentle than laboratory scale flexo units where the foil transport is either driven by the flexo unit or the flexo unit is driven by the foil transport. We demonstrate fully operational flexible polymer solar cell manufacture using this new roll and roll-to-roll (R3) approach and compare with the existing methods. [ABSTRACT FROM AUTHOR]

Abstract: Solar cells that convert sunlight into electrical power have demonstrated a large and consistent growth through several decades. The growth has spawned research on new technologies that potentially enable much faster, less costly and environmentally friendly manufacture from earth abundant materials. Here we review carbon based solar cells through a complete analysis of all the data that has been reported so far and we highlight what can be expected from carbon based technologies and draw scenarios of how it can be made of immediate use. [Copyright &y& Elsevier]

Abstract: The 3-dimensional imaging of complete polymer solar cells prepared by roll-to-roll coating was carried out using high-resolution 1322nm optical coherence tomography (OCT) system. We found it possible to image the 3-dimensional structure of the entire solar cell that comprises UV-barrier, barrier material, adhesive, substrate and active solar cell multilayer structure. The achievable resolution was 12μm in the lateral plane and 4.5μm in the depth. We found that the OCT technique could be readily employed to identify coating defects in the functional layers. We finally identify the limitations of the technique, and future developments that would strengthen the use of the technique are described. [Copyright &y& Elsevier]

Abstract: Large area polymer tandem solar cells completely processed using roll-to-roll (R2R) coating and printing techniques are demonstrated. A stable tandem structure was achieved by the use of orthogonal ink solvents for the coating of all layers, including both active layers. Processing solvents included water, alcohols and chlorobenzene. Open-circuit voltages close to the expected sum of sub cell voltages were achieved, while the overall efficiency of the tandem cells was found to be limited by the low yielding back cell, which was processed from water based ink. Many of the challenges associated with upscaling the multilayer tandem cells were identified giving valuable information for future experiments and development. [Copyright &y& Elsevier]

Abstract: Indium is a scarce and expensive material that has been identified as a bottleneck for future organic electronics deployment in large scale. Indium is the main constituent of Indium Tin Oxide (ITO), which is the most successful transparent electrode in organic photovoltaics (OPV) so far. A new process, termed Hiflex, allows for manufacture of flexible OPV modules where the ITO electrode has been replaced by a sputtered Al/Cr electrode in an inverted device architecture with front illumination. This work presents a life cycle assessment of the Hiflex process, in order to compare the environmental impact of avoiding ITO as electrode. The new ITO-free process reduces some of the processing steps, leading to important reductions of the energy input during OPV module manufacturing in comparison to ITO-based modules. The environmental analysis reveals an Energy Pay-Back time (EPBT) of 10 years due to the high-energy consumption of Al/Cr roll-to-roll sputtering and to the relatively low efficiency of the Hiflex OPV modules (≈1%). An optimization of the active area fraction could easily reduce the EPBT to ≈5 years. A further enhancement of the efficiency to 5% would give rise to a promising EPBT of only 1 year. Our work highlights that vacuum processing steps should be avoided. [Copyright &y& Elsevier]

Abstract: A life cycle analysis was performed on a full roll-to-roll coating procedure used for the manufacture of flexible polymer solar cell modules. The process known as ProcessOne employs a polyester substrate with a sputtered layer of the transparent conductor indium-tin-oxide (ITO). The ITO film was processed into the required pattern using a full roll-to-roll process, employing screen printing of an etch resist and then applying etching, stripping, washing and drying procedures. The three subsequent layers; ZnO, P3HT:PCBM and PEDOT:PSS were slot-die coated and the silver back electrode was screen printed. Finally the polymer solar modules were encapsulated, using a polyester barrier material. All operations except the application of ITO were carried out under ambient conditions. The life cycle analysis delivered a material inventory of the full process for a module production, and an accountability of the energy embedded both in the input materials and in the production processes. Finally, upon assumption of power conversion efficiencies and lifetime for the modules, a calculation of energy pay-back time allowed us to compare this roll-to-roll manufacturing with other organic and hybrid photovoltaic technologies. The results showed that an Energy Pay-Back Time (EPBT) of 2.02 years can be achieved for an organic solar module of 2% efficiency, which could be reduced to 1.35 years, if the efficiency was 3%. [Copyright &y& Elsevier]

Abstract: The business potential of polymer solar cells is reviewed and the market opportunities analyzed on the basis of the currently reported and projected performance and manufacturing cost of polymer solar cells. Possible new market areas are identified and described. An overview of the present patent and intellectual property situation is also given and a patent map of polymer solar cells is drawn in a European context. It is found that the business potential of polymer solar cells is large when taking the projections for future performance into account while the currently available performance and manufacturing cost leaves little room for competition on the thin film photovoltaic market. However, polymer solar cells do enable the competitive manufacture of low cost niche products and is viewed as financially viable in its currently available form in a large volume approximation. Finally, it is found that the polymer solar cell technology is very poorly protected in Europe with the central patents being valid in only France, Germany, the Netherlands and the United Kingdom. Several countries with a large potential for PV such as Portugal and Greece are completely open and have apparently no relevant patents. This is viewed as a great advantage for the possible commercialization of polymer solar cells in a European setting as the competition for the market will be based on the manufacturing performance rather than domination by a few patent stakeholders. [Copyright &y& Elsevier]

Abstract: The synthesis and characterization of a number of so-called thermo-cleavable solvents are described with their application in all-air, all-solution and all-screen-printed polymer solar cells. These solvents were developed to meet some requirements for printing techniques such as long “open time” combined with fast drying on heating that cannot be attained with the usual solvents used for conjugated polymers. The new solvents have low volatility at ambient conditions, but decompose thermally at 130–180°C to low-boiling and highly volatile products. Characterization by thermogravimetric analysis (TGA) and high-temperature NMR established the onset temperature of decomposition, the rate of the reaction and the nature of the products. Printing experiments with inks based on these solvents together with conjugated polymers are exemplified for polymer solar cell devices to show how they enable large-scale production of polymer solar cells using screen printing. Screen-printed solar cells are still very inferior to state of the art P3HT/PCBM technology, but it is our view that it is necessary to explore these printing technologies if polymer solar cells are to ever become commercial products. [Copyright &y& Elsevier]

Abstract: Multilayer tandem polymer solar cells were prepared by solution processing using thermocleavable polymer materials that allow for conversion to an insoluble state through a short thermal treatment. The problems associated with solubility during application of subsequent layers in the stack were efficiently solved. Devices comprised a transparent front cathode based on solution processed zinc oxide nanoparticles, a large band gap active layer based on a bulk heterojunction between zinc oxide and poly(3-carboxydithiophene) (P3CT) followed by a layer of PEDOT:PSS processed from water. The second cell in the stack employed a zinc oxide front cathode processed on top of the PEDOT:PSS layer from an organic solvent, a low band gap active layer based on a bulk heterojunction between zinc oxide and the novel poly(carboxyterthiophene-co-diphenylthienopyrazine) (P3CTTP) followed by a layer of PEDOT:PSS again processed from water and finally a printed silver electrode. The devices were prepared without the use of fullerenes and vacuum steps and employ only thermal treatments and orthogonal solvents. The devices exhibited operational stability in air without any form of encapsulation. [Copyright &y& Elsevier]

Abstract: Continuous operation of a polymer photovoltaic device under accelerated conditions for more than 1 year has been demonstrated (8760h at 72°C, 1000Wm−2, AM1.5, under vacuum). Formation of hydrogen-bonded networks is proposed to be responsible for the long lifetime and high stability observed in photovoltaic devices employing polythiophene substituted with carboxylic-acid moieties under oxygen free conditions. 1H and 13C solid-state NMR, IR, and ESR spectroscopy of unmodified and isotopically labeled polythiophenes were studied. Distances between the isotopically labeled carboxylic acid carbon atoms were measured by 13C solid-state magic-angle-spinning (MAS) NMR using symmetry-based double-quantum (2Q) dipolar recoupling. This revealed the presence of 13C–13C distances of 3.85Å, which correspond to the C–C distance in hydrogen-bonded carboxylic acid dimers. In spite of the presence of carboxylic groups in the polymer as demonstrated by 13C CP/MAS NMR and IR spectroscopy, the absence of carboxylic protons in solid state 1H NMR spectra indicate that they are mobile. We link the extraordinary stability of this system to the rigid nature, cross-linking through a hydrogen-bonded network and a partially oxidized state. [Copyright &y& Elsevier]