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Low Cost Manufacturing of Organic Solar Cells,[object Object],Vishal Shrotriya, Ph.D.,[object Object],Solarmer Energy, Inc.,[object Object],Printed Electronics USA  |  Nov 30 - Dec 2, 2010  |  Santa Clara, CA,[object Object]
Outline,[object Object],Introduction,[object Object],Materials for High Efficiency OPVs,[object Object],R2R Process Development,[object Object],Lifetime and Stability,[object Object],Products and Applications,[object Object],11/29/2010,[object Object],PE USA 2010,[object Object],2,[object Object]
OPV Timeline,[object Object],11/29/2010,[object Object],3,[object Object],Solarmer,[object Object],Before 2005,[object Object],Konarka,[object Object],8.13%,[object Object],7.9%,[object Object],Plextronics,[object Object],7.6%,[object Object],Solarmer,[object Object],6.4%,[object Object],6.8%,[object Object],6.0%,[object Object],Plextronics founded,[object Object],5.4%,[object Object],5.1%,[object Object],Konarka founded,[object Object],4.8%,[object Object],3.7%,[object Object],3.2%,[object Object],R2R line complete,[object Object],Solarmer’s R&D began,[object Object],Solarmer founded,[object Object],2.7%,[object Object],2007,[object Object],2009,[object Object],2005,[object Object],2008,[object Object],2006,[object Object],2004,[object Object],2003,[object Object],2002,[object Object],2001,[object Object],2011,[object Object],2010,[object Object],PE USA 2010,[object Object]
[object Object]
Acceptors
Interfaces
Device engineering
Materials stability
Barrier and adhesives
Testing standards
Manufacturability
Raw materialsOPV Technology,[object Object],4,[object Object],11/29/2010,[object Object],PE USA 2010,[object Object]
Materials Development,[object Object],Next 2 years,[object Object],2007-2010,[object Object],5,[object Object],PE USA 2010,[object Object],Assumptions: ,[object Object],[object Object]
FF = 65%Recent Results: ,[object Object],[object Object],	(White et al., APL 2008),[object Object],[object Object],Efficiency  up to 12% can be achieved for single cells,[object Object],Schraber et al., Adv Mater 2006.,[object Object],11/29/2010,[object Object]
Challenges,[object Object],Bang gap too large (1.9 eV for P3Ht vs. 1.1 eV for Si),[object Object],Low current density,[object Object],Non-optimized energy levels,[object Object],Low voltage,[object Object],Significant energy loss during charge transfer,[object Object],Low voltage,[object Object],Low mobility,[object Object],Low fill factor ,[object Object],11/29/2010,[object Object],6,[object Object],PE USA 2010,[object Object]
New Materials – LBG I,[object Object],PSBTBT,[object Object],JSC = 13.6 mA/cm2,[object Object],VOC = 0.66 V,[object Object],FF = 0.62,[object Object],PCE = 5.6%,[object Object],11/29/2010,[object Object],7,[object Object],PE USA 2010,[object Object]
New Materials – PTB,[object Object],PTB1,[object Object],VOC  = 0.58V,[object Object],JSC = 15 mA/cm2,[object Object],FF = 66%,[object Object],PCE = 6%,[object Object],11/29/2010,[object Object],8,[object Object],PE USA 2010,[object Object]
BDT Based Polymers,[object Object],Nature Photonics 2009, 3 (11), 649,[object Object],11/29/2010,[object Object],9,[object Object],PE USA 2010,[object Object]
BDT Based Polymers,[object Object],For OPV based on PBDTTT-CF:,[object Object],JSC    = 15.2 mA/cm2,[object Object],VOC   =  0.76 V,[object Object],FF     =  66.9 %	,[object Object],PCE  =  7.73 %,[object Object],Nature Photonics 2009, 3 (11), 649,[object Object],11/29/2010,[object Object],10,[object Object],PE USA 2010,[object Object]
Champion Cell (NREL Certified),[object Object],11/29/2010,[object Object],PE USA 2010,[object Object],11,[object Object],(Reported in July 2010),[object Object],VOC= 0.757 V,[object Object],JSC= 14.97 mA/cm2,[object Object],Fill Factor = 67.84%,[object Object],Efficiency = 8.13%,[object Object]
Champion Module,[object Object],11/29/2010,[object Object],PE USA 2010,[object Object],12,[object Object],* Certified by Newport Corp.,[object Object]
Materials Development Summary,[object Object],VOC tuning by applying electron-withdrawing groups which lower polymer’s HOMO,[object Object],Long wavelength absorption achieved through low band-gap which increases JSC,[object Object],More than 7% efficiency achieved in OPVs using BDT-based polymers,[object Object],Further improvement in efficiency is expected by increasing VOC by tuning polymer’s HOMO level,[object Object],11/29/2010,[object Object],PE USA 2010,[object Object],13,[object Object]
Low Cost Manufacturing,[object Object],Uses primarily existing technology,[object Object],Roll-to-roll for high throughput,[object Object],Low temperature process,[object Object],Non-vacuum process,[object Object],Low energy requirements,[object Object],Very high material utilization,[object Object],11/29/2010,[object Object],PE USA 2010,[object Object],14,[object Object]
Roll-to-Roll Process ,[object Object],15,[object Object],Lamination of high quality barrier film ,[object Object],Rotary Screen,,[object Object],Conductive paste,[object Object],Deposition head,,[object Object],Active layer ,[object Object],Deposition Head,,[object Object],HTL Layer,[object Object],Deposition Head,,[object Object],ETL Layer,[object Object],11/29/2010,[object Object],Cond Paste,[object Object],HTL/ETL,[object Object],Active ,[object Object],ETL/HTL,[object Object],ITO ,[object Object],PET,[object Object],PE USA 2010,[object Object]
Deposition ,[object Object],Head,[object Object],Problem Drivers:,[object Object],Low solid content (2-5%),[object Object],Low viscosity (10-150 cps),[object Object],Thickness,[object Object],Pattern,[object Object],Registration,[object Object],Solid ,[object Object],Content,[object Object],Solution ,[object Object],Viscosity,[object Object],Process Parameters ,[object Object],16,[object Object],11/29/2010,[object Object],PE USA 2010,[object Object]
Solution Deposition Technologies,[object Object],17,[object Object],17,[object Object],11/29/2010,[object Object],PE USA 2010,[object Object]
Coating Line Design,[object Object],18,[object Object],Air Nozzle,[object Object],Slot-Die,[object Object],11/29/2010,[object Object],PE USA 2010,[object Object]
Rewinding,[object Object],Dryer,[object Object],Oven,[object Object],Antistatic Bar,[object Object],Coating Head,[object Object],Unwinding ,[object Object],Plasma,[object Object],Treater,[object Object],Tacky Roll,[object Object],Backing Roll,[object Object],[object Object]
Multiple functions
Class 100/1000 clean room
Line speed: Up to 20 ft/minSolarmer’s OPV Pilot Line,[object Object],19,[object Object],11/29/2010,[object Object],PE USA 2010,[object Object]
Stability of OPVs,[object Object],Factors that affect stability,[object Object],Temperature,[object Object],Humidity,[object Object],Cycling of temp, %RH, light,[object Object],Load conditions,[object Object],Pre treatment (light soak, etc.),[object Object],Packaging,[object Object],Electrodes,[object Object],11/29/2010,[object Object],PE USA 2010,[object Object],20,[object Object],Light,[object Object],Temperature,[object Object],Humidity/,[object Object], Oxygen,[object Object]
Energy transfer from photo-excited polymer to adsorbed ground state oxygen molecules to form singlet oxygen,[object Object],Degradation Mechanisms,[object Object],11/29/2010,[object Object],21,[object Object],ONRSBIR Phase I Project,[object Object]

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Organic Solar Cells

Editor's Notes

  1. Reaction of PPV polymer with singlet oxygen, which adds to the vinylene bond to form intermediate dioxetane, followed by chain scission
  2. iPhone 4 Camera = $9.76 (Total = 187.51)Smart phone sales= 300 million in 2013 (OPV = 20% market share)Solar cell phone chargers sell for $50-100 todayOPV for soldiers = 19 sqft (for 3 days); total US soldiers = 1.4 millionOPV for ebook readers = 50% market share