Roll‐to‐Roll Slot–Die Coated Organic Photovoltaic (OPV) Modules with High Geometrical Fill Factors

Abstract

Flexible semi‐transparent organic photovoltaic (OPV) modules were manufactured by roll‐to‐roll slot–die coating of three functional layers [ZnO, photoactive layer, and poly(3,4‐ethylenedioxythiophene):poly(styrenesulfonate) (PEDOT:PSS)] and either the screen printing or inkjet printing of the top electrodes. A poly(3‐hexylthiophene):[6,6] phenyl C61‐butyric acid methyl ester (P3HT:PCBM) layer deposited from non‐chlorinated solvents was used as the absorber layer. The modules were realized by slot–die coating of the layers onto a laser‐patterned polyethylene terephthalate/indium‐tin oxide (PET/ITO) substrate, followed by laser structuring of all coated layers. The top electrodes were realized by high‐resolution printing, which, combined with laser patterning of other layers, enables manufacturing of the modules with high geometrical fill factor (92.5 %). The modules have an active area of 156 cm2, and contain 13 serially interconnected cells. Two semitransparent electrodes (ITO from the bottom and PEDOT:PSS/Ag‐grid from the top side) allow the absorption of photons incident from both sides. The performance of the modules was evaluated and compared among the modules by considering the following factors: (i) roll‐to‐roll slot–die coated vs. spin‐coated layers, (ii) inkjet‐printed vs. screen‐printed top electrodes, (iii) top vs. bottom illumination. The demonstrated technology is one of the proven feasible ways towards industrial manufacturing of the OPV modules.

Roll‐to‐Roll Fabrication of Solution Processed Electronics

“…Laser interconnection can significantly reduce the dead area and seems to be more effective for OPV manufacturing, as it can provide high GFFs of up to 95% . Holst Centre − Solliance has reported OPV modules prepared using three R2R slot die coated layers (ZnO/PAL/PEDOT:PSS; Figure ) and either screen printed or inkjet printed back electrodes . The interconnections in these modules were made by laser patterning, which provided a very high GFF of 92.5%.…”

“…The next important parameters which will bring the OPV technology closer to full scale commercialization are a high GFF, which already has been demonstrated in R2R coated modules and the freedom of forms, as has been demonstrated with inkjet printing or gravure printing . The remaining issues hampering mass production and full commercialization of OPVs are the still relatively low power conversion efficiencies and insufficient stability .…”

Laser-Patterning Engineering for Perovskite Solar Modules With 95% Aperture Ratio

“…[32] Generally, laser patterning in thin-film PV consists of three subsequent laser processes and thus, the process of laser-induced interconnection of solar cells in modules is called the P1-P2-P3 process. [31,[33][34][35][36] This approach permits the creation of a monolithic series-interconnected module. Through the P1-P2-P3 laser processing selective layer removal can be realized where required.…”

Research Update: Large-area deposition, coating, printing, and processing techniques for the upscaling of perovskite solar cell technology

“…A remarkable result was obtained also by the application of laser patterning to flexible modules, with a geometrical aperture ratio of up to 92.5%. 55 At the moment one of the best efficiencies for a perovskite based module is 13.6% over aperture area. 20 In this work the P1-P2-P3 patterning procedures played an important role, improving the aperture ratio up to 91%.…”