A universal roll‐to‐roll slot‐die coating approach towards high‐efficiency organic photovoltaics

Huang, Yu‐Ching; Cha, Hou‐Chin; Chen, Charn-Ying; Tsao, Cheng‐Si

doi:10.1002/pip.2907

Cited by 38 publications

(38 citation statements)

References 44 publications

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“…In addition, the performance degradation or morphological evolution caused by scaling up the area of the devices is also a critical challenge . Therefore, the lab‐to‐manufacturing translation from the record lab‐scale devices to industrial‐scale modules is a critical challenge for future applications …”

Section: Photovoltaic Performance Of Devices (Slot‐die) Based On Ptb7mentioning

confidence: 99%

A General Approach for Lab‐to‐Manufacturing Translation on Flexible Organic Solar Cells

et al. 2019

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The blossoming of organic solar cells (OSCs) has triggered enormous commercial applications, due to their high‐efficiency, light weight, and flexibility. However, the lab‐to‐manufacturing translation of the praisable performance from lab‐scale devices to industrial‐scale modules is still the Achilles' heel of OSCs. In fact, it is urgent to explore the mechanism of morphological evolution in the bulk heterojunction (BHJ) with different coating/printing methods. Here, a general approach to upscale flexible organic photovoltaics to module scale without obvious efficiency loss is demonstrated. The shear impulse during the coating/printing process is first applied to control the morphology evolution of the BHJ layer for both fullerene and nonfullerene acceptor systems. A quantitative transformation factor of shear impulse between slot‐die printing and spin‐coating is detected. Compelling results of morphological evolution, molecular stacking, and coarse‐grained molecular simulation verify the validity of the impulse translation. Accordingly, the efficiency of flexible devices via slot‐die printing achieves 9.10% for PTB7‐Th:PC71BM and 9.77% for PBDB‐T:ITIC based on 1.04 cm2 . Furthermore, 15 cm2 flexible modules with effective efficiency up to 7.58% (PTB7‐Th:PC71BM) and 8.90% (PBDB‐T:ITIC) are demonstrated with satisfying mechanical flexibility and operating stability. More importantly, this work outlines the shear impulse translation for organic printing electronics.

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Section: Photovoltaic Performance Of Devices (Slot‐die) Based On Ptb7mentioning

confidence: 99%

A General Approach for Lab‐to‐Manufacturing Translation on Flexible Organic Solar Cells

et al. 2019

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“…Zimmermann et al by coating the organic functional layers for inverted P3HT:PCBM solar cell modules on PET foil via the slot‐die method were able to achieve an FF of 0.64%. Similarly, Tsao and co‐workers developed a facile R2R slot‐die coating approach by combining the additive and the R2R oven temperatures, and achieved a 7.32% PCE based on PTB7:PC71BM:2%DIO system.…”

Section: Methods For Upscale Fabricationmentioning

confidence: 99%

“…The advantage of this type of assembly is that modules in series can be made with only one strip of the active layer. Huang et al similarly, processed series connected OSC modules (Figure b) based on R2R slot‐die coating on flexible substrates, and achieved a module PCE of 4.34% . Further, some creative modular designs have also been reported.…”

Section: Pce Losses From Small‐area To Large‐area Devices and To Modmentioning

confidence: 99%

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Large‐Area Organic Solar Cells: Material Requirements, Modular Designs, and Printing Methods

et al. 2018

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The printing of large‐area organic solar cells (OSCs) has become a frontier for organic electronics and is also regarded as a critical step in their industrial applications. With the rapid progress in the field of OSCs, the highest power conversion efficiency (PCE) for small‐area devices is approaching 15%, whereas the PCE for large‐area devices has also surpassed 10% in a single cell with an area of ≈1 cm2. Here, the progress of this fast developing area is reviewed, mainly focusing on: 1) material requirements (materials that are able to form efficient thick active layer films for large‐area printing); 2) modular designs (effective designs that can suppress electrical, geometric, optical, and additional losses, leading to a reduction in the PCE of the devices, as a consequence of substrate area expansion); and 3) printing methods (various scalable fabrication techniques that are employed for large‐area fabrication, including knife coating, slot‐die coating, screen printing, inkjet printing, gravure printing, flexographic printing, pad printing, and brush coating). By combining thick‐film material systems with efficient modular designs exhibiting low‐efficiency losses and employing the right printing methods, the fabrication of large‐area OSCs will be successfully realized in the near future.

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“…Although blading coating, as a prototyping tool for slot‐die coating, can get high performance larger area devices on glass substrate, which is comparable to the spin‐coated OSCs . The performance of slot‐die‐coated OSCs is limited due to more challenges in controlling the morphology of the active layer from the special rolling process . The photovoltaic progress using slot‐die coating on flexible substrates is summarized in Figure .…”

Section: Introductionmentioning

confidence: 99%

A Sequential Slot‐Die Coated Ternary System Enables Efficient Flexible Organic Solar Cells

Zhao

Wang

et al. 2019

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For the preparation of flexible organic solar cells (OSCs), the Roll‐to‐Roll slot‐die coating technique is preferable. Herein, a sequential slot‐die (SSD) coating strategy to fabricate flexible OSCs using non halogenated solvent under ambient atmosphere, is developed. The coating order of the active layer materials shows great influence on the performance of OSCs. It is found that, compared with the one‐step coating, the power conversion efficiency (PCE) of devices with an area of 0.75 cm2, and fabricated by SSD coating process with the polymer as the first layer, is enhanced from 4.86 to 5.51% for the binary system, whereas from 6.09 to 7.32% for the ternary system, showing an increase of 13 and 20% in PCE, respectively. For the devices with a standard small area of 4 mm2 and large area of 1 cm2, PCE as high as 9.36 and 7.11% are obtained, respectively, which are among the top value for flexible devices fabricated by slot‐die coating. It turns out that the SSD coating process with the polymer as the first layer assists pre‐aggregation of the polymer to form better crystal domains with face‐on orientation. Therefore, a sequential deposition strategy could provide a new means for manufacturing the high efficiency flexible OSCs.

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A universal roll‐to‐roll slot‐die coating approach towards high‐efficiency organic photovoltaics

Cited by 38 publications

References 44 publications

A General Approach for Lab‐to‐Manufacturing Translation on Flexible Organic Solar Cells

A General Approach for Lab‐to‐Manufacturing Translation on Flexible Organic Solar Cells

Large‐Area Organic Solar Cells: Material Requirements, Modular Designs, and Printing Methods

A Sequential Slot‐Die Coated Ternary System Enables Efficient Flexible Organic Solar Cells

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