Frederik C. Krebs

Stability of Polymer Solar Cells

Organic photovoltaics (OPVs) evolve in an exponential manner in the two key areas of efficiency and stability. The power conversion efficiency (PCE) has in the last decade been increased by almost a factor of ten approaching 10%. A main concern has been the stability that was previously measured in minutes, but can now, in favorable circumstances, exceed many thousands of hours. This astonishing achievement is the subject of this article, which reviews the developments in stability/degradation of OPVs in the last five years. This progress has been gained by several developments, such as inverted device structures of the bulk heterojunction geometry device, which allows for more stable metal electrodes, the choice of more photostable active materials, the introduction of interfacial layers, and roll-to-roll fabrication, which promises fast and cheap production methods while creating its own challenges in terms of stability.

A roll-to-roll process to flexible polymer solar cells: model studies, manufacture and operational stability studies

An inverted polymer solar cell geometry comprising a total of five layers was optimized using laboratory scale cells and the operational stability was studied under model atmospheres. The device geometry was substrate-ITO-ZnO-(active layer)-PEDOT:PSS-silver with P3HT-PCBM as the active layer. The inverted devices were compared to model devices with a normal geometry where the order of the layers was substrate-ITO-PEDOT:PSS-(active layer)-aluminium. In both cases illumination was through the substrate which requires that it is transparent. Both device types were optimized to a power conversion efficiency of 2.7% (1000 W m−2, AM1.5G, 72 ± 2 °C). The devices were operated under illumination while being subjected to different atmospheres to identify the dominant modes of degradation. Dry nitrogen (99.999%), dry oxygen (99.5%), humid nitrogen (90 ± 5% relative humidity) and ambient atmosphere (20% oxygen, 20 ± 5% relative humidity) were employed and both device types were found to be stable in a nitrogen atmosphere during the test period of 200 hours. The devices with a normal geometry where an aluminium electrode is employed gave stable operation in dry oxygen but did not give stable device operation in the presence of humidity. The inverted devices behaved oppositely where the less reactive silver electrode gave stable operation in the presence of humidity but poor stability in the presence of oxygen. The inverted model device was then used to develop a new process giving access to fully roll-to-roll (R2R) processed polymer solar cells entirely by solution processing starting from a polyethyleneterephthalate (PET) substrate with a layer of indium-tin-oxide (ITO). All processing was performed in air without vacuum coating steps and modules comprising eight serially connected cells gave power conversion efficiencies as high as 2.1% for the full module with 120 cm2 active area (AM1.5G, 393 W m−2) and up to 2.3% for modules with 4.8 cm2 active area (AM1.5G, 1000 W m−2).

The teraton challenge. A review of fixation and transformation of carbon dioxide

The increase in atmospheric carbon dioxide is linked to climate changes; hence there is an urgent need to reduce the accumulation of CO2 in the atmosphere. The utilization of CO2 as a raw material in the synthesis of chemicals and liquid energy carriers offers a way to mitigate the increasing CO2 buildup. This review covers six important CO2 transformations namely: chemical transformations, photochemical reductions, chemical and electrochemical reductions, biological conversions, reforming and inorganic transformations. Furthermore, the vast research area of carbon capture and storage is reviewed briefly. This review is intended as an introduction to CO2, its synthetic reactions and their possible role in future CO2 mitigation schemes that has to match the scale of man-made CO2 in the atmosphere, which rapidly approaches 1 teraton.

Upscaling of polymer solar cell fabrication using full roll-to-roll processing

Upscaling of the manufacture of polymer solar cells is detailed with emphasis on cost analysis and practical approach. The device modules were prepared using both slot-die coating and screen printing the active layers in the form of stripes that were serially connected. The stripe width was varied and the resultant performance analysed. Wider stripes give access to higher geometric fill factors and lower aperture loss while they also present larger sheet resistive losses. An optimum was found through preparation of serially connected stripes having widths of 9, 13 and 18 mm with nominal geometric fill factors (excluding bus bars) of 50, 67 and 75% respectively. In addition modules with lengths of 6, 10, 20, 22.5 and 25 cm were explored. The devices were prepared by full roll-to-roll solution processing in a web width of 305 mm and roll lengths of up to 200 m. The devices were encapsulated with a barrier material in a full roll-to-roll process using standard adhesives giving the devices excellent stability during storage and operation. The total area of processed polymer solar cell was around 60 m2 per run. The solar cells were characterised using a roll-to-roll system comprising a solar simulator and an IV-curve tracer. After characterisation the solar cell modules were cut into sheets using a sheeting machine and contacted using button contacts applied by crimping. Based on this a detailed cost analysis was made showing that it is possible to prepare complete and contacted polymer solar cell modules on this scale at an area cost of 89 euro m(-2) and an electricity cost of 8.1 euro Wp(-1). The cost analysis was separated into the manufacturing cost, materials cost and also the capital investment required for setting up a complete production plant on this scale. Even though the cost in euro Wp(-1) is comparable to the cost for electricity using existing technologies the levelized cost of electricity (LCOE) is expected to be significantly higher than the existing technologies due to the inferior operational lifetime. The presented devices are thus competitive for consumer electronics but ill-suited for on-grid electricity production in their current form.

Roll-to-roll fabrication of polymer solar cells

As the performance in terms of power conversion efficiency and operational stability for polymer and organic solar cells is rapidly approaching the key 10-10 targets (10 % efficiency and 10 years of stability) the quest for efficient, scalable, and rational processing methods has begun. The 10-10 targets are being approached through consistent laboratory research efforts, which coupled with early commercial efforts have resulted in a fast moving research field and the dawning of a new industry. We review the roll-to-roll processing techniques required to bring the magnificent 10-10 targets into reality, using quick methods with low environmental impact and low cost. We also highlight some new targets related to processing speed, materials, and environmental impact.

Advanced materials and processes for polymer solar cell devices

The rapidly expanding field of polymer and organic solar cells is reviewed in the context of materials, processes and devices that significantly deviate from the standard approach which involves rigid glass substrates, indium-tin-oxide electrodes, spincoated layers of conjugated polymer/fullerene mixtures and evaporated metal electrodes in a flat multilayer geometry. It is likely that significant advances can be found by pursuing many of these novel ideas further and the purpose of this review is to highlight these reports and hopefully spark new interest in materials and methods that may be performing less than the current state-of-the-art in their present form but that may have the potential to outperform these pending a larger investment in effort.

Product integration of compact roll-to-roll processed polymer solar cell modules: methods and manufacture using flexographic printing, slot-die coating and rotary screen printing

The improvement of the performance of roll-to-roll processed polymer solar cell modules through miniaturization of the device outline is described. The devices were prepared using full roll-to-roll processing comprising flexographic printing, slot-die coating and rotary screen printing to create 5 mm wide lines of ZnO, P3HT:[60/70]PCBM, PEDOT:PSS and silver on an ITO-PET substrate. The lines were spaced by 1 mm and the devices were completed by encapsulation using roll-to-roll lamination on both sides using a pressure sensitive adhesive and a multilayered barrier material having a UV-filter with a cut-off at 390 nm, oxygen and water vapor transmission rates of respectively 0.01 cm3 m−2 bar−1 day−1 and 0.04 g m−2 day−1. The final modules comprised 16 serially connected cells. The technical yield was 89% based on the criterion that the Voc had to be larger than 7.2 V. This set of modules gave respectively a voltage, current, fill factor and power conversion efficiency of 8.47 ± 0.41 V, −23.20 ± 4.10 mA, 35.4 ± 2.8% and 1.96 ± 0.34% in the case of modules based on P3HT:[60]PCBM. A total of 1960 modules were prepared for each run and the best power conversion reached was 2.75% for devices based on P3HT:[70]PCBM. The solar cell modules were used to demonstrate the complete manufacture of a small lamp entirely using techniques of flexible electronics. The solar cell module was used to charge a polymer lithium ion battery through a blocking diode. The entire process was fully automated and demonstrates the capacity of polymer solar cells in the context of flexible and printed electronics. Finally a comparison was made between the learning curve for OPV and crystalline silicon solar cells in terms of the cost per watt peak and the cumulative watt peak. OPV as a technology was found to have a significantly steeper learning curve.

Degradation Patterns in Water and Oxygen of an Inverted Polymer Solar Cell

The spatial distribution of reaction products in multilayer polymer solar cells induced by water and oxygen atmospheres was mapped and used to elucidate the degradation patterns and failure mechanisms in an inverted polymer solar cell. The active material comprised a bulk heterojunction formed by poly(3-hexylthiophene) (P3HT) and [6,6]-phenyl-C61-butyric acid methyl ester (PCBM) sandwiched between a layer of zinc oxide and a layer of poly(3,4-ethylenedioxythiophene) poly(styrenesulfonate) (PEDOT:PSS) that acted as, respectively, electron and hole transporting layers between the active material and the two electrodes indium-tin-oxide (ITO) and printed silver. X-ray photoelectron spectroscopy (XPS) and time-of-flight secondary ion mass spectrometry (TOF-SIMS) in conjunction with isotopic labeling using H(2)(18)O and (18)O(2) enabled detailed information on where and to what extent uptake took place. A comparison was made between the use of a humid (oxygen-free) atmosphere and a dry oxygen atmosphere during testing of devices that were kept in the dark and devices that were subjected to illumination under simulated sunlight. It was found that the reactions taking place at the interface between the active layer and the PEDOT:PSS were the major cause of device failure in the case of these inverted devices, which are compatible with full roll-to-roll (R2R) coating and industrial manufacture. The PEDOT:PSS was found to phase separate, with the PEDOT-rich phase being responsible for most of the interface degradation in oxygen atmospheres. In water atmospheres, little chemically induced degradation was observed, whereas a large partially reversible dependence of the open circuit voltage on the relative humidity was observed. In addition, temporal aspects are discussed in regard to degradation mechanisms. Finally, analytical aspects in regard to storing devices are discussed.

Manufacture, integration and demonstration of polymer solar cells in a lamp for the “Lighting Africa” initiative

Semitransparent flexible polymer solar cells were manufactured in a full roll-to-roll process under ambient conditions. After encapsulation a silver based circuit was printed onto the back side of the polymer solar cell module followed by sheeting and application of discrete components and vias. The discrete components were white light LEDs, a blocking diode, a lithium ion battery, vias and button contacts in two adjacent corners. The completed lamp has outside dimensions of 22.5 × 30.5 cm, a weight of 50 g and a very flat outline. The battery and components were the thickest elements and measured < 1 mm. A hole with a ring was punched in one corner to enable mechanical fixation or tying. The lamp has two states. In the charging state it has a completely flat outline and will charge the battery when illuminated from either side while the front side illumination is preferable. When used as a lamp two adjacent corners are joined via button contacts whereby the device can stand on a horizontal surface and the circuit is closed such that the battery discharges through the LEDs that illuminate the surface in front of the lamp. Several different lamps were prepared using the same solar cell and circuitry while varying the amount of white LEDs employed and by variation of the number of batteries and the individual battery capacity. The lamp prototype was developed through two early prototypes and the final and serially produced prototype was subjected to field tests in Zambia. Some of the lamps were recovered and the experiences gained with the prototype are presented allowing for further development that takes systemic factors such as the immediate response and spontaneous handling of the lamp by someone with no prior knowledge of the lamp or its workings.

Solar cells with one-day energy payback for the factories of the future

Scalability is a requirement before any new energy source can be expected to house a possible solution to the challenge that mankind’s increasing energy demand presents. No renewable energy source is as abundant as the Sun and yet efficient and low-cost conversion of solar energy still has not been developed. We approach the challenge by firstly taking a technology that efficiently addresses the need for daily production of 1 GWp on a global level, which does not employ elements with critically low abundance and has a low thermal budget. We then applied life cycle assessment methodologies to direct research and developed such technology in the form of a polymer solar cell that presents a significant improvement in energy payback time (EPBT) and found that very short energy payback times on the order of one day are possible, thus potentially presenting a solution to the current energy gap of >14 TW by year 2050.