The fabrication of organic photovoltaic modules via printing techniques has been the greatest challenge for their commercial manufacture. Current module architecture, which is based on a monolithic geometry consisting of serially interconnecting stripe-patterned subcells with finite widths, requires highly sophisticated patterning processes that significantly increase the complexity of printing production lines and cause serious reductions in module efficiency due to so-called aperture loss in series connection regions. Herein we demonstrate an innovative module structure that can simultaneously reduce both patterning processes and aperture loss. By using a charge recombination feature that occurs at contacts between electron- and hole-transport layers, we devise a series connection method that facilitates module fabrication without patterning the charge transport layers. With the successive deposition of component layers using slot-die and doctor-blade printing techniques, we achieve a high module efficiency reaching 7.5% with area of 4.15 cm2.

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The manufacture of thin film transistors with reliable electrical properties, via full-printing on plastic foils, is a key step for the realization of costless and flexible electronics. To reach this goal, the dielectric layers should be smooth and free from failure while maintaining a high capacitance. In this paper, the parameters, affecting the film quality and capacitance of dielectric layers in a roll-to-roll gravure process, were investigated and some parameters were optimized.