Markus Hösel

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.

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.

Scalable, ambient atmosphere roll-to-roll manufacture of encapsulated large area, flexible organic tandem solar cell modules

Inline printing and coating methods have been demonstrated to enable a high technical yield of fully roll-to-roll processed polymer tandem solar cell modules. We demonstrate generality by employing different material sets and also describe how the ink systems must be carefully co-developed in order to reach the ambitious objective of a fully printed and coated 14-layer flexible tandem solar cell stack. The roll-to-roll methodologies involved are flexographic printing, rotary screen printing, slot-die coating, X-ray scattering, electrical testing and UV-lamination. Their combination enables the manufacture of completely functional devices in exceptionally high yields. Critical to the ink and process development is a carefully chosen technology transfer to industry method where first a roll coater is employed enabling contactless stack build up, followed by a small roll-to-roll coater fitted to an X-ray machine enabling in situ studies of wet ink deposition and drying mechanisms, ultimately elucidating how a robust inline processed recombination layer is key to a high technical yield. Finally, the transfer to full roll-to-roll processing is demonstrated.

Large scale deployment of polymer solar cells on land, on sea and in the air

With the development of patterns that connect all cells in series, organic photovoltaics have leapt a step forward being ahead of other solar and even other energy technologies in terms of manufacturing speed and energy density. The important questions of how they are meant to be installed for producing power and what the requirements are yet to be explored. We present here the installation of organic solar cell modules in different settings (terrestrial, marine and airborne). For the evaluation of these installations deployed at DTU, we have used the life cycle assessment tools, and calculated key parameters in order to assess their environmental impact. The novel technology when installed in a solar park system can generate more than 1300 kW h kWp−1 of electricity a year, which means that the whole system can pay the energy invested back before the first year of operation, in 320 days. If this electricity is fed back to the same electricity supply system that was used for manufacturing the potential saving of more than 13 GJ of primary energy per kWp per year can be reached. With the real data logged, a dynamic energy payback time has been furthermore calculated for the case of the solar tube installation, giving a value of 1.1 years.

The ISOS-3 inter-laboratory collaboration focused on the stability of a variety of organic photovoltaic devices

Seven distinct sets (n ≥ 12) of state of the art organic photovoltaic devices were prepared by leading research laboratories in a collaboration planned at the Third International Summit on Organic Photovoltaic Stability (ISOS-3). All devices were shipped to RISO DTU and characterized simultaneously up to 1830 h in accordance with established ISOS-3 protocols under three distinct illumination conditions: accelerated full sun simulation; low level indoor fluorescent lighting; and dark storage with daily measurement under full sun simulation. Three nominally identical devices were used in each experiment both to provide an assessment of the homogeneity of the samples and to distribute samples for a variety of post soaking analytical measurements at six distinct laboratories enabling comparison at various stages in the degradation of the devices. Over 100 devices with more than 300 cells were used in the study. We present here design and fabrication details for the seven device sets, benefits and challenges associated with the unprecedented size of the collaboration, characterization protocols, and results both on individual device stability and uniformity of device sets, in the three illumination conditions.

Large-scale roll-to-roll photonic sintering of flexo printed silver nanoparticle electrodes

In this report we employ static and roll-to-roll (R2R) photonic sintering processes on flexo printed silver nanoparticle-based electrode structures with a heat-sensitive 60 μm thin barrier foil as a substrate. We use large area electrode structures to visualize the increased optical footprint of single and quadruple flashes, and the R2R challenges in the form of overlapping exposures. It is shown that single flash exposure is enough to significantly increase the conductivity and adhesion without damaging the foil or build-up of cracks in the silver layer. Additional flash exposures or increased energies above the threshold level have only minor impact on the conductivity but lead to cracks and substrate deformation. A second silver nanoparticle ink was printed, which was already optimized for low-temperature drying. Here we show that photonic sintering has only a minor impact on the conductivity as the nanoparticles are already sintered. The advantage of single exposure is the ability to produce higher R2R processing speeds without overlapping, which is shown in the form of theoretical calculations.

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

We present a cost analysis based on state of the art printing and coating processes to fully encapsulated, flexible ITO- and vacuum-free polymer solar cell modules. Manufacturing data for both single junctions and tandem junctions are presented and analyzed. Within this calculation the most expensive layers and processing steps are identified. Based on large roll-to-roll coating experiments the exact material consumptions were determined. In addition to the data for the pilot scale experiment presented here, projections to medium and large scale scenarios serve as a guide to achieve cost targets of 5 €ct per Wp in a detailed material and cost analysis. These scenarios include the replacement of cost intensive layers, as well as process optimization steps. Furthermore, the cost structures for single and tandem devices are listed in detail and discussed. In an optimized model the material costs drop below 10 € per m2 which proves that OPV is a competitive alternative to established power generation technologies.

High‐Volume Processed, ITO‐Free Superstrates and Substrates for Roll‐to‐Roll Development of Organic Electronics

The fabrication of substrates and superstrates prepared by scalable roll‐to‐roll methods is reviewed. The substrates and superstrates that act as the flexible carrier for the processing of functional organic electronic devices are an essential component, and proposals are made about how the general availability of various forms of these materials is needed to accelerate the development of the field of organic electronics. The initial development of the replacement of indium‐tin‐oxide (ITO) for the flexible carrier materials is described and a description of how roll‐to‐roll processing development led to simplification from an initially complex make‐up to higher performing materials through a more simple process is also presented. This process intensification through process simplification is viewed as a central strategy for upscaling, increasing throughput, performance, and cost reduction.

Solution processed large area fabrication of Ag patterns as electrodes for flexible heaters, electrochromics and organic solar cells

A simple method for producing patterned Ag electrodes on transparent and flexible substrates is reported. The process makes use of a laser printed toner as a sacrificial template for an organic precursor, which upon thermolysis and toner lift off produced highly conducting Ag electrodes. Thus, the process takes only a few minutes without any expensive instrumentation. The electrodes exhibited excellent adhesion and mechanical properties, important for flexible device applications. Using Ag patterned electrodes, heaters operating at low voltages, pixelated electrochromic displays as well as organic solar cells have been demonstrated. The method is extendable to produce defect-free patterns over large areas as demonstrated by roll coating.

Rapid flash annealing of thermally reactive copolymers in a roll-to-roll process for polymer solar cells

Light induced thermocleaving of a thermally reactive copolymer based on dithienylthiazolo[5,4-d]thiazole (DTZ) and silolodithiophene (SDT) in contact with the heat sensitive substrate the heat sensitive substrate polyethyleneterphthalate (PET) was effectively demonstrated with the use of high intensity pulsed light, delivered by a commercial photonic sintering system. Thermally labile ester groups are positioned on the DTZ unit of the copolymer that can be eliminated thermally for enhanced photochemical stability and advantages in terms of processing (solubility/insolubility switching). The photonic sintering system was successfully implemented in a full roll-to-roll process on flexible PET substrates and large-area polymer solar cell modules were prepared by solution processing of five layers under ambient conditions using the photonic sintering system for thermocleaving of the active layer. The PET foil did not show any deformation after exposure to the high intensity light only leaving the insoluble thermocleaved active layer. The active layer remained planar after light exposure thereby allowing the coating of supplementary material on top.