Pathways to Upscaling Highly Efficient Organic Solar Cells Using Green Solvents: A Study on Device Photophysics in the Transition from Lab-to-Fab.

As the rise of nonfullerene acceptors (NFA) has allowed lab-scale organic solar cells (OSC) to reach 20% efficiency, translating these devices into roll-to-roll compatible fabrication still poses many challenges for researchers. Among these are the use of green solvent solubility for large-scale manufacture, roll-to-roll compatible fabrication, and, not least, information on charge carrier dynamics in each upscaling step, to further understand the gap in performance. In this work, the reproducibility of champion devices using slot-die coating with 14% power conversion efficiency (PCE) is demonstrated, under the condition that the optimal thickness is maintained. It is further shown that for the donor:acceptor (D:A) blend PM6:Y12, the processing solvent has a more significant impact on charge carrier dynamics compared to the deposition technique. It is found that the devices processed with o-xylene feature a 40% decrease in the bimolecular recombination coefficient compared to those processed with CB, as well as a 70% increase in effective mobility. Finally, it is highlighted that blade-coating yields devices with similar carrier dynamics to slot-die coating, making it the optimal choice for lab-scale optimization with no significant loss in translation toward up-scale.

Efficiency-Enhanced Scalable Organic Photovoltaics Using Roll-to-Roll Nanoimprint Lithography.

Invited for this month's cover is the group of Prof. Morten Madsen, University of Southern Denmark, together with Stensborg A/S and Dr. Shalev's group at the Ben-Gurion University of the Negev. The image shows the integration of Roll-to-Roll (R2R) light-management foils to enhance efficiency of R2R organic photovoltaics. The Full Paper itself is available at 10.1002/cssc.202101611.

Efficiency-Enhanced Scalable Organic Photovoltaics Using Roll-to-Roll Nanoimprint Lithography.

Light-trapping nanostructures have for decades been researched as a route to enhance the performance of organic solar cells (OSCs). Whereas the power conversion efficiencies (PCEs) of OSCs have reached above 18 %, industrially compatible devices made by scalable processing in air, using only nontoxic solvents and materials, have shown significantly lower performance values. Although light-trapping nanostructures may improve this, the methods for integrating the nanostructures are typically not compatible with industrial scale up. In this work, scalable, industrially compatible, nonfullerene-based OSCs are developed with integrated light-trapping nanostructures at the back electrodes in the devices. The OSCs are made by using scalable roll-to-roll (R2R) and sheet-to-sheet (S2S) processes and the nanostructures are made by using roll-to-plate (R2P) nanoimprint lithography. A fully scalable solution is thereby developed for industrially compatible nanostructured OSCs. The nanostructured devices show enhancements in PCE up to 25 % compared to reference cells, owing to an enhancement in the short-circuit current density (15 %) by enhanced absorption, and improved charge carrier extraction leading to an enhancement in the fill factor (7 %). Optical modeling is utilized to verify the optical effect of the nanostructures. The best devices attain a PCE of 6.5 %, which is the highest reported efficiency for air-processed slot-die coated ITO-free flexible PBDB-T : ITIC devices, here using nontoxic solvents.

Inverted organic solar cells with non-clustering bathocuproine (BCP) cathode interlayers obtained by fullerene doping.

Bathocuproine (BCP) is a well-studied cathode interlayer in organic photovoltaic (OPV) devices, where it for standard device configurations has demonstrated improved electron extraction as well as exciton blocking properties, leading to high device efficiencies. For inverted devices, however, BCP interlayers has shown to lead to device failure, mainly due to the clustering of BCP molecules on indium tin oxide (ITO) surfaces, which is a significant problem during scale-up of the OPV devices. In this work, we introduce C70 doped BCP thin films as cathode interlayers in inverted OPV devices. We demonstrate that the interlayer forms smooth films on ITO surfaces, resulting from the introduction of C70 molecules into the BCP film, and that these films possess both improved electron extraction as well exciton blocking properties, as evidenced by electron-only devices and photoluminescence studies, respectively. Importantly, the improved cathode interlayers leads to well-functioning large area (100 mm2) devices, showing a device yield of 100%. This is in strong contrast to inverted devices based on pure BCP layers. These results are founded by the effective suppression of BCP clustering from C70, along with the electron transport and exciton blocking properties of the two materials, which thus presents a route for its integration as an interlayer material towards up-scaled inverted OPV devices.

Degradation pathways in standard and inverted DBP-C70 based organic solar cells.

Achieving long-term stability in organic solar cells is a remaining bottleneck for the commercialization of this otherwise highly appealing technology. In this work, we study the performance and stability differences in standard and inverted DBP/C70 based organic solar cells. Differences in the charge-transfer state properties of inverted and standard configuration DBP/C70 solar cells are revealed by sensitive external quantum efficiency measurements, leading to differences in the open-circuit voltages of the devices. The degradation of standard and inverted solar cell configurations at ISOS aging test conditions (ISOS-D-3 and ISOS-T-3) was investigated and compared. The results indicate that the performance drop in the small molecule bilayer solar cells is less related to changes at the D-A interface, suggesting also a pronounced morphological stability, and instead, in the case of inverted cells, dominated by degradation at the electron transport layer (ETL) bathocuproine (BCP). Photoluminescence measurements, electron-only-device characteristics, and stability measurements show improved exciton blocking, electron transport properties and a higher stability for BCP/Ag ETL stacks, giving rise to inverted devices with enhanced performance and device stability.

Area dependent behavior of bathocuproine (BCP) as cathode interfacial layers in organic photovoltaic cells.

Standard and inverted configuration small molecule OPV cells incorporating bathocuproine (BCP) as electron transport and exciton blocking layer is investigated, demonstrating that 2 mm2 standard and inverted cells display a maximum performance for BCP thicknesses of 10 nm and 1.5 nm, respectively. The reason for the different optimum BCP thicknesses for the two device configurations is the BCP-metal complex formed between the Ag electrode and the BCP layer in the standard configuration OPV devices. Interestingly, at optimum BCP thicknesses, the inverted OPV cells outperform the standard devices. Upon up-scaling of the device area of the cells from 2 mm2 to 10 and 100 mm2, device failure becomes prominent for the inverted OPV cells, due to aggregation of the evaporated BCP layer on the ITO surface. This demonstrates that although BCP can be adopted for efficient ETL in inverted configuration OPV devices on small scale, it is not suitable for device up-scaling due to severely decreasing device yields. In this work, a possible solution where an ultrathin layer of C70 is evaporated between the ITO and BCP layer is proposed. It is demonstrated that the proposed solution holds a strong potential to minimize the device failures of the BCP based inverted OPV cells to a significant extent, while maintaining good device performances.

ITO with embedded silver grids as transparent conductive electrodes for large area organic solar cells.

In this work, development of semi-transparent electrodes for efficient large area organic solar cells (OSCs) has been demonstrated. Electron beam evaporated silver grids were embedded in commercially available ITO coatings on glass, through a standard negative photolithography process, in order to improve the conductivity of planar ITO substrates. The fabricated electrodes with embedded line and square patterned Ag grids reduced the sheet resistance of ITO by 25% and 40%, respectively, showing optical transmittance drops of less than 6% within the complete visible light spectrum for both patterns. Solution processed bulk heterojunction OSCs based on PTB7:[70]PCBM were fabricated on top of these electrodes with cell areas of 4.38 cm2, and the performance of these OSCs was compared to reference cells fabricated on pure ITO electrodes. The Fill Factor (FF) of the large-scale OSCs fabricated on ITO with embedded Ag grids was enhanced by 18% for the line grids pattern and 30% for the square grids pattern compared to that of the reference OSCs. The increase in the FF was directly correlated to the decrease in the series resistance of the OSCs. The maximum power conversion efficiency (PCE) of the OSCs was measured to be 4.34%, which is 23% higher than the PCE of the reference OSCs. As the presented method does not involve high temperature processing, it could be considered a general approach for development of large area organic electronics on solvent resistant, flexible substrates.