Suren A. Gevorgyan

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).

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.

The OE-A OPV demonstrator anno domini 2011

Polymer solar cells were prepared in large numbers using roll-to-roll methods and were subsequently integrated into the Organic Electronics Association (OE-A) demonstrator in the year 2011 and presented as a small credit card sized lamp with a flat outline. The lamp comprised the polymer solar cell together with printed circuitry, discrete components and flexible lithium polymer batteries. The number of discrete steps required for the manufacture of the lamp was 35 and more than 10 000 units of the demonstrator was manufactured. We describe the efforts towards increasing the technical yield which was 89% overall and discuss the compromises that had to be made to achieve the high technical yield for a process that was as automated as possible. All the steps in the preparation of the solar cell, the circuitry and the overlays were performed using full roll-to-roll methods. The mounting of the discrete components, such as LED, diode and Zener diode, was performed in sheets of 15 units using a fully automated SMD mounting machine. The mounting of the batteries, contacts and final testing was done manually. The lamination into the final lamp and the final laser cutting into the discrete lamps were performed using automated systems.

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.

“Hairy” Poly(3-hexylthiophene) Particles Prepared via Surface-Initiated Kumada Catalyst-Transfer Polycondensation

Herein, we present a new paradigm in the engineering of nanostructured hybrids between conjugated polymer and inorganic materials via a chain-growth surface-initiated Kumada catalyst-transfer polycondensation (SI-KCTP) from particles. Poly(3-hexylthiophene), P3HT, a benchmark material for organic electronics, was selectively grown by SI-KCTP from (nano)particles bearing surface-immobilized Ni catalysts supported by bidentate phosphorus ligands, that resulted in hairy (nano)particles with end-tethered P3HT chains. Densely grafted P3HT chains exhibit strongly altered optical properties compared to the untethered counterparts (red shift and vibronic fine structure in absorption and fluorescence spectra), as a result of efficient planarization and chain-aggregation. These effects are observed in solvents that are normally recognized as good solvents for P3HT (e.g., tetrahydrofurane). We attribute this to strong interchain interactions within densely grafted P3HT chains, which can be tuned by changing the surface curvature (or size) of the supporting particle. The hairy P3HT nanoparticles were successfully applied in bulk heterojunction solar cells.

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.

Aesthetically Pleasing Conjugated Polymer:Fullerene Blends for Blue-Green Solar Cells Via Roll-to-Roll Processing

The practical application of organic photovoltaic (OPV) cells requires high throughput printing techniques in order to attain cells with an area large enough to provide useful amounts of power. However, in the laboratory screening of new materials for OPVs, spin-coating is used almost exclusively as a thin-film deposition technique due its convenience. We report on the significant differences between the spin-coating of laboratory solar cells and slot-die coating of a blue-green colored, low bandgap polymer (PGREEN). This is one of the first demonstrations of slot-die-coated polymer solar cells OPVs not utilizing poly(3-hexylthiophene):(6,6)-phenyl-C(61)-butyric acid methyl ester (PCBM) blends as a light absorbing layer. Through synthetic optimization, we show that strict protocols are necessary to yield polymers which achieve consistent photovoltaic behavior. We fabricated spin-coated laboratory scale OPV devices with PGREEN: PCBM blends as active light absorbing layers, and compare performance to slot die-coated individual solar cells, and slot-die-coated solar modules consisting of many cells connected in series. We find that the optimum ratio of polymer to PCBM varies significantly when changing from spin-coating of thinner active layer films to slot-die coating, which requires somewhat thicker films. We also demonstrate the detrimental impacts on power conversion efficiency of high series resistance imparted by large electrodes, illustrating the need for higher conductivity contacts, transparent electrodes, and high mobility active layer materials for large-area solar cell modules.

Thermocleavable Materials for Polymer Solar Cells with High Open Circuit Voltage-A Comparative Study

The search for polymer solar cells giving a high open circuit voltage was conducted through a comparative study of four types of bulk-heterojunction solar cells employing different photoactive layers. As electron donors the thermo-cleavable polymer poly-(3-(2-methylhexyloxycarbonyl)dithiophene) (P3MHOCT) and unsubstituted polythiophene (PT) were used, the latter of which results from thermo cleaving the former at 310 degrees C. As reference, P3HT solar cells were built in parallel. As electron acceptors, either PCBM or bis-[60]PCBM were used. In excess of 300 solar cells were produced under as identical conditions as possible, varying only the material combination of the photo active layer. It was observed that on replacing PCBM with bis[60]PCBM, the open circuit voltage on average increased by 100 mV for P3MHOCT and 200 mV for PT solar cells. Open circuit voltages approaching 1 V were observed for the PT:bis[60]PCBM solar cells and a maximum conversion efficiency of 1.3% was obtained for solar cells with P3MHOCT:PCBM as the photoactive material. For the reference solar cells maximum efficiencies of 2.1 and 2.4% were achieved for P3HT:PCBM and P3HT:bis[60]PCBM, respectively. Despite special measures taken in terms of substrate design and device processing, a substantial spread in the photovoltaic properties was generally observed. This spread could not be correlated with the optical properties of the solar cells, the thickness of the photo active layer or the electrode deposition conditions of the aluminum top electrode.

Cyclopolymerization-derived block-copolymers of 4,4-bis(octyloxymethyl)-1,6-heptadiyne with 4,4- dipropargyl malonodinitrile for use in photovoltaics

The synthesis of AB-type block copolymers of 4,4-bis(octyloxymethyl)-1,6-heptadiyne (M1) and dipropargyl malonodinitrile (M2) via metathesis-based cyclopolymerization using well-defined molybdenum- and ruthenium-based initiators is described. While backbiting reactions were observed in the case where polymerizations were triggered by [Ru(NCO)2(IMesH2)(CH-2-(2-PrO)–C6H4] (I2) and [Ru(NCO)2(3-Br-Py)2(IMesH2)(CHPh)] (I3), (IMesH2 = 1,3-dimesitylimidazolin-2-ylidene, 3-Br-Py = 3-bromopyridine), the use of RuCl2(Py)2(IMesH2)(CHPh) (I1) in THF allowed for the synthesis of poly(M1) without any backbiting, though with a broad PDI. Block copolymers, i.e. poly(M1)-b-poly(M2), could be prepared in a living manner without any backbiting by the use of the Mo-based Schrock-type initiator Mo(N-2,6-i-Pr2C6H3)(CHCMe2Ph)(OCH(CH3)2)2 (I4) and THF as solvent. Poly(M1)-b-poly(M2) was characterized by UV and fluorescence spectroscopy and used for the construction of a photovoltaic device.