Patterning of organic photovoltaic modules by ultrafast laser

Abstract

In this paper, we demonstrate that laser patterning of organic solar cells by ultrafast laser systems (pulse length <350 fs) is an attractive process to produce photovoltaic modules with outstanding high geometric fill factors. Moreover, in terms of precision, registration, and debris generation and in terms of keeping the damage to the underneath layers at a minimum, ultrafast laser patterning with a pulse length of few hundreds of femtoseconds turns out to yield superior results. Ablation of all three different solar cell layers (electrodes (P1 and P3) and interfaces and semiconductor (P2)) is achieved with a single wavelength simply by a precise adjustment of the laser fluence and the patterning overlap. Camera positioning allows a precise registration between the various processing steps and a reduction of the width of the overall interconnection regime to the hundreds of micrometers dimension, resulting in high geometrical fill factors of over 90% for monolithically interconnected organic solar cell modules.

Cost analysis of roll-to-roll fabricated ITO free single and tandem organic solar modules based on data from manufacture

“…In the upscaling and the industrial scenario higher values were used according to estimations and predictions for an optimized processed area coverage: 75% for the upscaling and 98% for the industrial scenario. 25 The electrode materials are known to be one of the highest cost factors. In our models we used (a) Ag electrodes, (b) Ag front and aluminum back electrode and (c) carbon electrodes.…”

Flexible organic tandem solar modules with 6% efficiency: combining roll-to-roll compatible processing with high geometric fill factors

“…20 The concept was recently introduced by Kubis et al who presented laser patterned OPV single junction modules based on ITO-metal (silver)-ITO (IMI) electrodes. 33 Here the serial interconnection between individual cells is accomplished with ultrafast depth-resolved laser patterning.…”

“…2a). 20 The greatest challenge in implementing an efficient module derives mainly from the tradeoff between the quality and the size of the interconnection area (dead area, Fig. 2a).…”

Highly efficient, large area, roll coated flexible and rigid OPV modules with geometric fill factors up to 98.5% processed with commercially available materials

“…Laser structuring by fs-lasers has already proven to be a successful candidate for monolithic integration of thin film solar cells with patterning lengths as small as 150 mm. 21,22 In this work, we have managed to reduce this value to as little as 80 mm. Following the prescriptions (i) to (iii), a suitable module layout was chosen (Fig.…”