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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]

Silver nanowires (AgNWs) and zinc oxide (ZnO) are deposited on flexible substrates using fast roll-to-roll (R2R) processing. The AgNW film on polyethylene terephthalate (PET) shows >80% uniform optical transmission in the range of 550-900 nm. This electrode is compared to the previously reported and currently widely produced indium-tin-oxide (ITO) replacement comprising polyethylene terephthalate (PET)|silver grid|poly(3,4-ethylenedioxythiophene):poly(styrenesulfonate) (PEDOT:PSS)|ZnO known as Flextrode. The AgNW/ZnO electrode shows higher transmission than Flextrode above 490 nm in the electromagnetic spectrum reaching up to 40% increased transmission at 750 nm in comparison to Flextrode. The functionality of AgNW electrodes is demonstrated in single and tandem polymer solar cells and compared with parallel devices on traditional Flextrode. All layers, apart from the semitransparent electrodes which are large-scale R2R produced, are fabricated in ambient conditions on a laboratory roll-coater using printing and coating methods which are directly transferrable to large-scale R2R processing upon availability of materials. In a single cell structure, Flextrode is preferable with active layers based on poly-3-hexylthiophene(P3HT):phenyl-C61-butyric acid methylester (PCBM) and donor polymers of similar absorption characteristics while AgNW/ZnO electrodes are more compatible with low band gap polymer-based single cells. In tandem devices, AgNW/ZnO is more preferable resulting in up to 80% improvement in PCE compared to parallel devices on Flextrode. [ABSTRACT FROM AUTHOR]

The results presented demonstrate how the screening of 104 light-absorbing low band gap polymers for suitability in roll coated polymer solar cells can be accomplished through rational synthesis according to a matrix where 8 donor and 13 acceptor units are organized in rows and columns. Synthesis of all the polymers corresponding to all combinations of donor and acceptor units is followed by characterization of all the materials with respect to molecular weight, electrochemical energy levels, band gaps, photochemical stability, carrier mobility, and photovoltaic parameters. The photovoltaic evaluation is carried out with specific reference to scalable manufacture, which includes large area (1 cm2), stable inverted device architecture, an indium-tin-oxide-free fully printed flexible front electrode with ZnO/PEDOT:PSS (poly(3,4-ethylenedioxythiophene):polystyrene sulfonate), and a printed silver comb back electrode structure. The matrix organization enables fast identification of active layer materials according to a weighted merit factor that includes more than simply the power conversion efficiency and is used as a method to identify the lead candidates. Based on several characteristics included in the merit factor, it is found that 13 out of the 104 synthesized polymers outperformed poly(3-hexylthiophene) under the chosen processing conditions and thus can be suitable for further development. [ABSTRACT FROM AUTHOR]

As mass-produced, low-cost organic electronics enter our everyday lives, so does the waste from them. The challenges associated with end-of-life management must be addressed by careful design and carbon-based electrodes are central to these developments. Here, the reproducible production of vacuum-, indium tin oxide (ITO)-, and silver-free solar cells in a fully packaged form using only roll-to-roll processing is reported. Replacing silver with carbon as electrode material significantly lowers the manufacturing cost and makes the organic photovoltaic (OPV) modules environmentally safe while retaining their flexibility, active area efficiency, and stability. The substitution of silver with carbon does not affect the roll-to-roll manufacturing of the modules and allows for the same fast printing and coating. The use of carbon as electrode material is one step closer to the wide release of low-cost plastic solar cells and opens the door to new possible applications where silver recycling is not manageable. [ABSTRACT FROM AUTHOR]

ABSTRACT Two low-band gap polymer series based on benzo[1,2- b:4,5- b′]dithiophene (BDT) and dithienylbenzothiadiazole, with different numbers of fluorine substituents on the 2,3,1-benzothiadiazole unit, have been synthesized and explored in a comparative study of the photochemical stability and operational lifetime in flexible large area roll-coated bulk heterojunction solar cells. The two polymer series have different side chains on the BDT unit, namely 2-hexyldecyloxy (BDTHDO) ( P1-P3) or 2-hexyldecylthiophene (BDTTHD) ( P4-P6). The photochemical stability clearly shows that the stability enhances along with the number of fluorine atoms incorporated on the polymer backbone. Fabrication of the polymer solar cells based on the materials was carried out in ambient atmosphere on a roll coating/printing machine employing flexible and indium-tin-oxide-free plastic substrates. Solar cells based on the P4-P6 series showed the best performance, reaching efficiencies up to 3.8% for an active area of 1 cm2, due to an enhanced current compared to P1-P3. Lifetime measurements, carried out according to international summit on OPV stability (ISOS), of encapsulated devices reveals an initial fast decay for P1-P6 in the performance followed by a much slower decay rate, still retaining 40-55% of their initial performance after 250 h of testing under ISOS-L-1 conditions. © 2014 Wiley Periodicals, Inc. J. Polym. Sci., Part B: Polym. Phys. 2014, 52, 893-899 [ABSTRACT FROM AUTHOR]

In article number 1402186, Eva Bundgaard and co‐workers present a large study via which a library of conjugated polymers is developed to identify lead candidates that are suitable for indium tin oxide (ITO)‐free, flexible polymer solar cells that are fully printed under ambient conditions. Based on several characteristics, 13 lead candidates are found, out of the 104 synthesized polymers. The variation in light absorption (color) of the 104 synthesized polymers is shown on the cover. Cover picture by Markus Hösel. [ABSTRACT FROM AUTHOR]