Conjugated Polymers Via Direct Arylation Polymerization in Continuous Flow: Minimizing the Cost and Batch-to-Batch Variations for High-Throughput Energy Conversion.

Continuous flow methods are utilized in conjunction with direct arylation polymerization (DArP) for the scaled synthesis of the roll-to-roll compatible polymer, poly[(2,5-bis(2-hexyldecyloxy)phenylene)-alt-(4,7-di(thiophen-2-yl)-benzo[c][1,2,5]thiadiazole)] (PPDTBT). PPDTBT is based on simple, inexpensive, and scalable monomers using thienyl-flanked benzothiadiazole as the acceptor, which is the first ß-unprotected substrate to be used in continuous flow via DArP, enabling critical evaluation of the suitability of this emerging synthetic method for minimizing defects and for the scaled synthesis of high-performance materials. To demonstrate the usefulness of the method, DArP-prepared PPDTBT via continuous flow synthesis is employed for the preparation of indium tin oxide (ITO)-free and flexible roll-coated solar cells to achieve a power conversion efficiency of 3.5% for 1 cm2 devices, which is comparable to the performance of PPDTBT polymerized through Stille cross coupling. These efforts demonstrate the distinct advantages of the continuous flow protocol with DArP avoiding use of toxic tin chemicals, reducing the associated costs of polymer upscaling, and minimizing batch-to-batch variations for high-quality material.

In situ electrical and thermal monitoring of printed electronics by two-photon mapping.

Printed electronics is emerging as a new, large scale and cost effective technology that will be disruptive in fields such as energy harvesting, consumer electronics and medical sensors. The performance of printed electronic devices relies principally on the carrier mobility and molecular packing of the polymer semiconductor material. Unfortunately, the analysis of such materials is generally performed with destructive techniques, which are hard to make compatible with in situ measurements, and pose a great obstacle for the mass production of printed electronics devices. A rapid, in situ, non-destructive and low-cost testing method is needed. In this study, we demonstrate that nonlinear optical microscopy is a promising technique to achieve this goal. Using ultrashort laser pulses we stimulate two-photon absorption in a roll coated polymer semiconductor and map the resulting two-photon induced photoluminescence and second harmonic response. We show that, in our experimental conditions, it is possible to relate the total amount of photoluminescence detected to important material properties such as the charge carrier density and the molecular packing of the printed polymer material, all with a spatial resolution of 400 nm. Importantly, this technique can be extended to the real time mapping of the polymer semiconductor film, even during the printing process, in which the high printing speed poses the need for equally high acquisition rates.

Highly Conformal Ni Micromesh as a Current Collecting Front Electrode for Reduced Cost Si Solar Cell.

Despite relatively high manufacturing cost, crystalline-Si solar cell continues to hold promising future due to its high energy conversion efficiency and long life. As regards cost, one pertinent issue is the top electrode metallization of textured cell surface, which typically involves screen printing of silver paste. The associated disadvantages call for alternative methods that can lower the cost without compromising the solar cell efficiency. In the present work, a highly interconnected one-dimensional (1D) metal wire network has been employed as front electrode on conventional Si wafers. Here, for the first time, we report an innovative solution based crackle templating method for conformal metal wire network patterning over large textured surfaces. Laser beam induced current mapping showed uniform photocurrent collection by the electrodes without any shadow losses. With electroless deposition of Ni wire network on corrugated solar cell, a short circuit current of 33.28 mA/cm2 was obtained in comparison to 20.53 mA/cm2 without the network electrode. On comparing the efficiency with the conventional cells with screen printed electrodes, a 20% increment in efficiency has been observed. Importantly, the estimated manufacturing cost is at least two orders lower.

Flow Synthesis of Silver Nanowires for Semitransparent Solar Cell Electrodes: A Life Cycle Perspective.

Silver nanowires (AgNWs) were prepared on a 5 g scale using either the well-known batch synthesis following the polyol method or a new flow synthesis method. The AgNWs were employed as semitransparent electrode materials in organic photovoltaics and compared to traditional printed silver electrodes based on micron sized silver flakes using life cycle analysis and environmental impact analysis methods. The life cycle analysis of AgNWs confirms that they provide an avenue to low-impact semitransparent electrodes. We find that the benefit of AgNWs in terms of embodied energy is less pronounced than generally assumed but that the toxicological and environmental benefits are significant.

Roll-to-roll printed silver nanowires for increased stability of flexible ITO-free organic solar cell modules.

We report the use of roll-to-roll printed silver nanowire networks as front electrodes for fully roll-to-roll processed flexible indium-tin-oxide (ITO) free OPV modules. We prepared devices with two types of back electrodes, a simple PEDOT: PSS back electrode and a PEDOT: PSS back electrode with a printed silver grid in order to simultaneously explore the influence of the back electrode structure on the operational stability of the modules that did not include any UV-protection. We subjected the devices to stability testing under a number of protocols recommended by the international summit on OPV stability (ISOS). We explored accelerated ISOS-D-2, ISOS-D-3, ISOS-L-2, ISOS-L-3, ISOS-O-1 and ISOS-O-2 testing protocols and compared the performance to previous reports employing the same testing protocols on devices with PEDOT: PSS instead of the silver nanowires in the front electrode. We find significantly increased operational stability across all ISOS testing protocols over the course of the study and conclude that replacement of PEDOT: PSS in the front electrode with silver nanowires increase operational stability by up to 1000%. The duration of the tests were in the range of 140-360 days. The comparison of front and back electrode stability in this study shows that the modules with silver nanowire front electrodes together with a composite back electrode comprising PEDOT: PSS and a silver grid present the best operational stability.

The solar textile challenge: how it will not work and where it might.

Solar textiles are highlighted as a future technology with transformative power within the fields of both textiles and solar cells provided that developments are made in critical areas. Specifically, these are fundamental solutions to materials and material combinations with mechanical stability and flexibility imposed by textile architectures, scientific solutions to achieve high carrier transport efficiency and optical transmission in a textile topology, technical solutions to controlling the physical disposition of the anode and cathode along with their specific and error-free contacting and, finally, practical solutions to fast and efficient manufacture and integration. The areas of application and the penetration of solar textiles into our everyday life are expected to be explosive pending efficient developments within these four key areas. A shortcoming in one or more of these will, however, lead to the solar textiles being banned to academic existence.

Roll-Coated Fabrication of Fullerene-Free Organic Solar Cells with Improved Stability.

Large area, fullerene-free organic solar cells with improved stability and efficiency of up to 1% are fabricated by the roll-coating process on indium tin oxide free and flexible substrates, under ambient conditions.

Comparative Indoor and Outdoor Degradation of Organic Photovoltaic Cells via Inter-laboratory Collaboration.

We report on the degradation of organic photovoltaic (OPV) cells in both indoor and outdoor environments. Eight different research groups contributed state of the art OPV cells to be studied at Pomona College. Power conversion efficiency and fill factor were determined from IV curves collected at regular intervals over six to eight months. Similarly prepared devices were measured indoors, outdoors, and after dark storage. Device architectures are compared. Cells kept indoors performed better than outdoors due to the lack of temperature and humidity extremes. Encapsulated cells performed better due to the minimal oxidation. Some devices showed steady aging but many failed catastrophically due to corrosion of electrodes not active device layers. Degradation of cells kept in dark storage was minimal over periods up to one year.

From the bottom up--flexible solid state electrochromic devices.

Solid-state flexible polymer-based electrochromic devices are fabricated continuously by stacking layers in one direction. This novel bottom-up approach with no need for a lamination step is realized through in situ photo-crosslinking of the electrolyte using a "curing-chamber" fitted to a roll-coater, which lowers the oxygen concentration at the electrolyte surface. This enables fully printed and 2D patterned organic electrochromics.

25th anniversary article: Rise to power--OPV-based solar parks.

A solar park based on polymer solar cells is described and analyzed with respect to performance, practicality, installation speed, and energy payback time. It is found that a high voltage installation where solar cells are all printed in series enables an installation rate in Watts installed per minute that far exceed any other PV technology in existence. The energy payback time for the practical installation of polymer solar cell foil on a wooden 250 square meter platform in its present form is 277 days when operated in Denmark and 180 days when operated in southern Spain. The installation and de-installation rate is above 100 m min⁻¹, which, with the present performance and web width, implies installation of >200 W min⁻¹. In comparison, this also exceeds the overall manufacturing speed of the polymer solar cell foil with a width of 305 mm which is currently 1 m min⁻¹ for complete encapsulated and tested foil. It is also significant that simultaneous installation and de-installation which enables efficient schemes for decommissioning and recycling is possible. It is highlighted where research efforts should most rationally be invested in order to make grid electricity from OPV a reality (and it is within reach).

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.

Conductance enhancement of InAs/InP heterostructure nanowires by surface functionalization with oligo(phenylene vinylene)s.

We have investigated the electronic transport through 3 µm long, 45 nm diameter InAs nanowires comprising a 5 nm long InP segment as electronic barrier. After assembly of 12 nm long oligo(phenylene vinylene) derivative molecules onto these InAs/InP nanowires, we observed a pronounced, nonlinear I-V characteristic with significantly increased currents of up to 1 µA at 1 V bias, for a back-gate voltage of 3 V. As supported by our model calculations based on a nonequilibrium Green Function approach, we attribute this effect to charge transport through those surface-bound molecules, which electrically bridge both InAs regions across the embedded InP barrier.

Ambient fabrication of flexible and large-area organic light-emitting devices using slot-die coating.

The grand vision of manufacturing large-area emissive devices with low-cost roll-to-roll coating methods, akin to how newspapers are produced, appeared with the emergence of the organic light-emitting diode about 20 years ago. Today, small organic light-emitting diode displays are commercially available in smartphones, but the promise of a continuous ambient fabrication has unfortunately not materialized yet, as organic light-emitting diodes invariably depend on the use of one or more time- and energy-consuming process steps under vacuum. Here we report an all-solution-based fabrication of an alternative emissive device, a light-emitting electrochemical cell, using a slot-die roll-coating apparatus. The fabricated flexible sheets exhibit bidirectional and uniform light emission, and feature a fault-tolerant >1-µm-thick active material that is doped in situ during operation. It is notable that the initial preparation of inks, the subsequent coating of the constituent layers and the final device operation all could be executed under ambient air.

Silver front electrode grids for ITO-free all printed polymer solar cells with embedded and raised topographies, prepared by thermal imprint, flexographic and inkjet roll-to-roll processes.

Semitransparent front electrodes for polymer solar cells, that are printable and roll-to-roll processable under ambient conditions using different approaches, are explored in this report. The excellent smoothness of indium-tin-oxide (ITO) electrodes has traditionally been believed to be difficult to achieve using printed front grids, as surface topographies accumulate when processing subsequent layers, leading to shunts between the top and bottom printed metallic electrodes. Here we demonstrate how aqueous nanoparticle based silver inks can be employed as printed front electrodes using several different roll-to-roll techniques. We thus compare hexagonal silver grids prepared using either roll-to-roll inkjet or roll-to-roll flexographic printing. Both inkjet and flexo grids present a raised topography and were found to perform differently due to only the conductivity of the obtained silver grid. The raised topographies were compared with a roll-to-roll thermally imprinted grid that was filled with silver in a roll-to-roll process, thus presenting an embedded topography. The embedded grid and the flexo grid were found to perform equally well, with the flexographic technique currently presenting the fastest processing and the lowest silver use, whereas the embedded grid presents the maximally achievable optical transparency and conductivity. Polymer solar cells were prepared in the same step, using roll-to-roll slot-die coating of zinc oxide as the electron transport layer, poly-3-hexylthiophene:phenyl-C(61)-butyric acid methyl ester (P3HT:PCBM) as the active layer and poly(3,4-ethylenedioxythiophene):poly(styrenesulfonate) (PEDOT:PSS) as the top electrode, along with a flat bed screen printed silver grid. The power conversion efficiency (PCE) obtained for large area devices (6 cm(2)) was 1.84%, 0.79% and 1.72%, respectively, for thermally imprinted, inkjet and flexographic silver grids, tested outside under the real sun. Central to all three approaches was that they employed environmentally friendly solvents, i.e. water based nanoparticle silver inks.

On the stability of a variety of organic photovoltaic devices by IPCE and in situ IPCE analyses--the ISOS-3 inter-laboratory collaboration.

This work is part of the inter-laboratory collaboration to study the stability of seven distinct sets of state-of-the-art organic photovoltaic (OPV) devices prepared by leading research laboratories. All devices have been shipped to and degraded at RISØ-DTU up to 1830 hours in accordance with established ISOS-3 protocols under defined illumination conditions. In this work, we apply the Incident Photon-to-Electron Conversion Efficiency (IPCE) and the in situ IPCE techniques to determine the relation between solar cell performance and solar cell stability. Different ageing conditions were considered: accelerated full sun simulation, low level indoor fluorescent lighting and dark storage. The devices were also monitored under conditions of ambient and inert (N(2)) atmospheres, which allows for the identification of the solar cell materials more susceptible to degradation by ambient air (oxygen and moisture). The different OPVs configurations permitted the study of the intrinsic stability of the devices depending on: two different ITO-replacement alternatives, two different hole extraction layers (PEDOT:PSS and MoO(3)), and two different P3HT-based polymers. The response of un-encapsulated devices to ambient atmosphere offered insight into the importance of moisture in solar cell performance. Our results demonstrate that the IPCE and the in situ IPCE techniques are valuable analytical methods to understand device degradation and solar cell lifetime.

TOF-SIMS investigation of degradation pathways occurring in a variety of organic photovoltaic devices--the ISOS-3 inter-laboratory collaboration.

The present work is the fourth (and final) contribution to an inter-laboratory collaboration that was planned at the 3rd International Summit on Organic Photovoltaic Stability (ISOS-3). The collaboration involved six laboratories capable of producing seven distinct sets of OPV devices that were degraded under well-defined conditions in accordance with the ISOS-3 protocols. The degradation experiments lasted up to 1830 hours and involved more than 300 cells on more than 100 devices. The devices were analyzed and characterized at different points of their lifetimes by a large number of non-destructive and destructive techniques in order to identify specific degradation mechanisms responsible for the deterioration of the photovoltaic response. Work presented herein involves time-of-flight secondary ion mass spectrometry (TOF-SIMS) in order to study chemical degradation in-plane as well as in-depth in the organic solar cells. Various degradation mechanisms were investigated and correlated with cell performance. For example, photo-oxidation of the active material was quantitatively studied as a function of cell performance. The large variety of cell architectures used (some with and some without encapsulation) enabled valuable comparisons and important conclusions to be drawn on degradation behaviour. This comprehensive investigation of OPV stability has significantly advanced the understanding of degradation behaviour in OPV devices, which is an important step towards large scale application of organic solar cells.

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.

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.

Generation of native polythiophene/PCBM composite nanoparticles via the combination of ultrasonic micronization of droplets and thermocleaving from aqueous dispersion.

We report the preparation of native polythiophene (n-PT)/[6, 6]-phenyl-C61-butyric acid methyl ester (PCBM) composite nanoparticles from a poly[3-(2-methylhex-2-yl)oxy-carbonyldithiophene] (P3MHOCT)/PCBM aqueous dispersion prepared from an ultrasonically generated emulsion. The subsequent steps involve both ultrasonic generation of microdroplets in argon as a carrier gas and drying followed by thermocleaving of the P3MHOCT component in the gas phase. The chemical transition from P3MHOCT to n-PT was confirmed by Fourier transform infrared (FTIR) spectroscopy. The morphology and size of n-PT/PCBM nanoparticles were determined by atomic force microscopy (AFM), small-angle x-ray scattering (SAXS) and grazing incidence SAXS (GISAXS), giving an average size of ∼ 140 nm. The GISAXS results reveal that n-PT/PCBM nanoparticles pack in an ordered structure as opposed to the P3MHOCT/PCBM nanoparticles. The successful vapour-phase preparation of phase-separated n-PT/PCBM nanoparticles provides a new route to all-aqueous processing of conjugated materials relevant to efficient polymer solar cells with long operational stability. The use of ultrasound was involved in both liquid and gas phases demonstrating it as a low-cost processing method.