Abstract
We describe the fabrication of roll-to-roll (R2R) printed
organic photovoltaic (OPV) modules using gravure printing
and rotary screen-printing processes. These
two-dimensional printing techniques are differentiating
factors from coated OPVs enabling the direct patterning
of arbitrarily shaped and sized features into visual
shapes and, increasing the freedom to connect the cells
in modules. The inverted OPV structures comprise five
layers that are either printed or patterned in an R2R
printing process. We examined the rheological properties
of the inks used and their relationship with the
printability, the compatibility between the processed
inks, and the morphology of the R2R-printed layers. We
also evaluate the dimensional accuracy of the printed
pattern, which is an important consideration in designing
arbitrarily-shaped OPV structures. The photoactive layer
and top electrode exhibited excellent cross-dimensional
accuracy corresponding to the designed width. The
transparent electron transport layer extended 300 µm
beyond the designed values, whereas the hole transport
layer shrank 100 µm. We also examined the repeatability
of the R2R fabrication process when the active area of
the module varied from 32.2 cm2 to 96.5 cm2. A thorough
layer-by-layer optimization of the R2R printing processes
resulted in realization of R2R-printed 96.5 cm2 sized
modules with a maximum power conversion efficiency of
2.1% (mean 1.8%) processed with high functionality.
Original language | English |
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Pages (from-to) | 9570-9580 |
Journal | Nanoscale |
Volume | 7 |
Issue number | 21 |
DOIs | |
Publication status | Published - 2015 |
MoE publication type | A1 Journal article-refereed |