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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 enabling fabrication of polymer solar cells comprising five layers on flexible substrates is presented. The device geometry is inverted and allow for fabrication on both transparent and non-transparent flexible substrates. The process is illustrated in this work by formation of a bottom electrode comprising silver nanoparticles on a 130 micron thick polyethyleneternaphthalate (PEN) substrate. Subsequently an electron transporting layer of zinc oxide nanoparticles was applied from solution followed by an active layer of P3HT-PCBM and a hole transporting layer of PEDOT:PSS. These first four layers were applied by slot-die coating. The final electrode was applied by screen printing a grid structure that allowed for transmission of 80% of the light. The materials were patterned into stripes allowing for formation of a single cell device and serially connected modules comprising 2, 3 and 8 stripes. All five layers in the device were processed from solution in air and no vacuum steps were employed. An additional advantage is that the use of indium-tin-oxide (ITO) is avoided in this process. The devices were tested under simulated sunlight (1000Wm−2, AM1.5G) and gave a typical performance 0.3% in terms of power conversion efficiency (PCE) for the active layer. The low PCE was due to poor transmission of light through the back electrode. [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: Preliminary data on the fabrication of 0.1m2 polymer solar cells are presented. The process employed screen-printing of an active layer onto an indium-tin-oxide (ITO) electrode pattern (50Ωsquare−1) on a 200μm polyethyleneterphthalate (PET) substrate. After the printing, vacuum coating of an optional layer of C60 and the final aluminium electrode was employed to complete the device. The active layer consisted of poly-1,4-(2-methoxy-5-ethylhexyloxy)phenylenevinylene (MEH-PPV). Chlorobenzene was used as solvent for the screen-printing process. The design of the solar cell module was chosen to employ both serial and parallel connection of individual solar cells. Thirteen individual solar cells with an active area of 7.2cm2 were thus connected in series. The serial connection was chosen to reduce the current density for the large area employed. A step up in voltage is thus preferable to avoid resistive loss. The parallel connection of seven such rows through a screen-printed silver bus gave a solar cell module measuring 40cm×25cm (0.1m2). The active area was 65% of the total area. The remaining 35% of the area was used for interconnections between cells and for the separation between rows. The 65% active area was chosen to encompass a good margin for prototyping/research and to keep contact resistances between the cells low. In a fully automated process the active area could perhaps reach 90–99% interval but problems with current extraction and interconnections were found to become very critical. There are obvious shortcomings to this approach but the advantage of low current density is believed to be the biggest problem in efficient energy extraction from the module when no simple method for reducing the sheet resistance is available. In the simple geometry ITO/MEH-PPV/aluminium the module gave an open circuit voltage (V oc) of 10.5V, a short circuit current (I sc) of 5μA, a fill factor (FF) of 13% and an efficiency (η) of 0.00001% under AM1.5 illumination with an incident light intensity of 1000Wm−2. A geometry employing a sublimed layer of C60 (ITO/MEH-PPV/C60/Al) improved V oc, I sc, FF and η to 3.6V, 178μA, 19% and 0.0002%, respectively. The lifetimes (τ ½) of the devices defined as the time it takes for the module efficiency to attain half of its maximum value were found to improve significantly when a sublimed layer of C60 was included between the polymer and the aluminium electrode. The modules were laminated with 200μm polyethyleneterephthalate (PET) foil to mechanically protect the cells. τ ½ values of 150h were typically obtained. This short lifetime is linked to reaction between the reactive metal electrode (aluminium) and the constituents of the active layer. The modules were tested outdoors in different weather condition (wind, high temperature excursion, rain, snow). Tested during a storm the polymer photovoltaic laminate was subject to vibration stress and deformation and delamination in the organic layer was observed with fast bleaching of the active material. Efficient encapsulation with barriers that has very low oxygen and water permeabilities will be needed before future commercialisation can be anticipated. [Copyright &y& Elsevier]

Copolymers based on dithieno[3,2-b:2′,3′-d]silole (DTS) and dithienylthiazolo[5,4- d]thiazole (TTz) are synthesized and tested in an all-solution roll process for polymer solar cells (PSCs). Fabrication of polymer:[6,6]-phenyl-C61-butyric acid methyl ester (PCBM) solar cells is done on a previously reported compact coating/printing machine, which enables the preparation of PSCs that are directly scalable with full roll-to-roll processing. The positioning of the side-chains on the thiophene units proves to be very significant in terms of solubility of the polymers and consequently has a major impact on the device yield and process control. The most successful processing is accomplished with the polymer, PDTSTTz-4, that has the side-chains situated in the 4-position on the thiophene units. Inverted PSCs based on PDTSTTz-4 demonstrate high fill factors, up to 59%, even with active layer thicknesses well above 200 nm. Power conversion efficiencies of up to 3.5% can be reached with the roll-coated PDTSTTz-4:PCBM solar cells that, together with good process control and high device yield, designate PDTSTTz-4 as a convincing candidate for high-throughput roll-to-roll production of PSCs. [ABSTRACT FROM AUTHOR]

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]

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: 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: Manufacturing of flexible ITO-free polymer solar cell modules by roll-to-roll methods (R2R) is described. Inverted devices with top illumination were built on a Kapton foil and an Aluminum/Chromium bi-layer system was used as electron contact. The layer structure was Kapton/Al/Cr/P3HT:PCBM/PEDOT:PSS/Ag (printed) and devices were encapsulated. Small area cells (3cm2 active area) were first carefully optimized investigating the influence of a number of discrete parameters on performance. A maximum power conversion efficiency of 1.4% was achieved under 1 sun illumination (AM 1.5G, 1000Wm−2). Optimized lab-scale single devices were then transferred to a full R2R process combining slot-die coating and screen printing. All the layers were processed from solution under ambient conditions. Two different concepts were explored: (i) serially connected stripe modules (to reduce the Ohmic losses) and (ii) monolithic modules (to achieve high geometric fill factor and increase the flexibility of the process). For this second concept, the only layer that needs to be patterned is the silver grid electrode and the grid pattern design can then be readily tuned. As an example, four different patterns were used and the resultant performances compared. Modules comprising 16 serially connected cells gave total area efficiencies up to 0.5% (235cm2 – 1% on the active area) while the best monolithic ones gave 0.35% (100cm2 – 0.4% on the active area). The freshly prepared devices consistently showed an inflection point in the IV curve indicative of a rather poor photovoltaic behavior. Upon light exposure and repeated IV scans the inflection point partially disappeared, and performance significantly increased. [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: Optical spacer layers based on titaniumalkoxide precursor solutions were prepared by spin-coating on top of bulk heterojunction layers based on poly-3-hexylthiophene (P3HT) and phenyl-C61-butyric acid methylester (PCBM). Models and experiment have shown that the performance of polymer solar cells can improve upon application of an optical spacer by shifting the maximum of the electrical field vector of the incident light into the active layer. This avoids the so called “dead zone” close to the reflective electrode. We demonstrate a simple linear model that can be used to predict the intensity variations of the electrical field vector of the incident light through a multilayer structure. Central to our study is the thickness of the optical layer and we find that it is critical to control the optical spacer thickness on the actual active layer employed. X-ray reflectometry allows for the simultaneous determination of the active layer thickness and of the optical spacer layer. [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]