Publication date: 17th February 2025
Organic photovoltaics (OPV) is a rapidly emerging PV technology that enables solar cells and modules to be processed from solution. Recently, the power conversion efficiency (PCE) of small (<0.1 cm2) OPV cells has surpassed the 20% mark for the first time. However, the PCE of larger-area cells and modules is still significantly lower, which limits industrial application to date. Hence, there is an urgent need for research focused on the upscaling of OPV and its production processes to the module level.
In this work, a systematic upscaling of fully solution-processed PM6:Y6-C12:PC61BM devices processed in ambient air from non-halogenated solvents is presented. Simulation-assisted stack optimizations are used to boost the PCE of 1 cm2 cells to 15.9%. For semi-transparent devices, the evaporated silver electrode is replaced by a printed silver nanowire electrode. Homogeneous coatings on large areas are enabled by a specially developed accelerated blade coating process that is based on computational fluid dynamics (CFD) simulations. Additional electrical finite element method (FEM) simulations are used to optimize the solar module layout by minimizing the inevitable losses caused by the electrodes’ resistivity and the inactive interconnect areas. Finally, fully printed semi-transparent modules with 11.8% PCE on >200 cm² and analogous opaque large-area modules with 14.5% certified PCE (current world record) are demonstrated.
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