A R&D cluster bringing thin film solar energy technology to excellence

Size: px

Start display at page:

Download "A R&D cluster bringing thin film solar energy technology to excellence"

Laurence Armstrong
6 years ago
Views:

1 SOLLIANCE A R&D cluster bringing thin film solar energy technology to excellence Solliance OPV: Towards Low Cost, Efficient and Stable Organic Photovoltaic Modules Ronn Andriessen

2 Solliance OPV Program Introduction Presentation Introduction General Goal Current Status Way-of-Working Acknowledgements

for applied scientific research and strong in generic technologies Holst Centre, a joint research initiative of

3 3 Solliance partners ECN, the leading energy research institute in the Netherlands, Europe Imec, a world-leading research institute in nanoelectronics, based in Flanders, Belgium, Europe TNO, the leading Dutch (Europe) institute for applied scientific research and strong in generic technologies Holst Centre, a joint research initiative of imec en TNO located in Eindhoven, the Netherlands, Europe TU/e, Eindhoven University of Technology, the Netherlands, Europe

4 4 Shared Research Centre on Thin Film PV 3 thin film PV technologies connected by Generic enabling technologies 1. TF-Si 2. TF-CIGS 3. TF-OPV A. Transparent Conductive Layers B. Barriers and Encapsulation C. Interconnection D. Light Management E. Manufacturing Technologies: Vacuum F. Manufacturing Technologies: Wet Chemical G. Modeling & Characterisation H. Modules & Integration I. Equipment Design & Engineering

5 Solliance: open thin film PV research lines Local government investment Move of thin film PV activities of ECN to Eindhoven, the Netherlands Alliance of ECN, TNO, TU/e,

5 5 Solliance: open thin film PV research lines Local government investment Move of thin film PV activities of ECN to Eindhoven, the Netherlands Alliance of ECN, TNO, TU/e, Holst Centre and IMEC Investment in new Solliance building Investment of new infrastructure CIGS: S2S vacuum R2R ambient tf-si: R2R OPV: S2S and R2R ambient Artist impression

6 6 Impression new Solliance HTC Expected Q2 2013

7 Solliance OPV Program General Goal Presentation Introduction General Goal Current Status Way-of-Working Acknowledgements

8 Working principle OPV: Bulk Heterojunction 8 The donor and acceptor are nanoscopically mixed to overcome ~10 nm exciton diffusion length and increase donor/acceptor interface. metal top electrode transparent bottom electrode glass - D A ( O OMe e - 45 fs OMe ) O n Recombination: from µs to ms Light MDMO-PPV as donor (D) PCBM as acceptor (A) R. H. Friend et al., Nature, 1995, 376, 498 A. J. Heeger et al., Science, 1995, 270, 1789 N.S. Sariciftci et al., Science, 1992, 258, 1474 C.J. Brabec et al., Chem. Phys. Lett, 2001, 340(3,4), 232

9 9 Solliance OPV Program General goals Creation of a complete technology toolbox for the design, processing, integration and characterization of OPV cells and modules To unify the extremes of the well-known triangle (for dedicated applications) Efficiency Lifetime Cost By operating under the open innovation model i.e. shared research together with companies belonging to the value chain of OPV

10 10 Performance, lifetime & Processing Roadmap E L E L E L C

11 Solliance Technology Roadmap for OPV 11 OPV now: ~ 10 /Wp (~ 150 /m 2 ) R2R Slot-die coating (halogen based?) Anode based on: Vacuum sputtering of ITO Cell: ~ 10 % PCE Module: ~ 1,7% PCE Low production yield Low-end packaging via lamination OPV 2015: < 0.5 /Wp (< 50 /m2) Foil or film based Printed/Coated halogen-free Anode based on: Direct printing of TC and metal Cell: 13 % PCE Module: > 5 % PCE 20% production yield increase High-end barrier technology < 10 % PCE-loss after C/45% RH, 1 sun

12 New planned OPV facilities R2R up to 30 cm width 20 m 16,5 m No clean room Clean room 4 m 2,40 m 12 Eindhoven to be reintegrated and extended Minimum need for clean room For OPV but also for other thin film PV like e.g. CIGS but also for OLED Easy extensible 20 m Foil U-turner DM4DM3DM2DM1 DM8DM7DM6DM5DM4DM3DM2DM1 DM4DM3DM2DM1 1,5 2 m Dryer Module x (DMx) R2R line 3 R2R line 2 R2R line 1 Post cure Deposition R2R nanoimprint R2R lamination R2R metal 1,20 m Inspection & Alignment Cleaning & Alignment 4 m Roll-on Roll-off 1,20 m 1,20 m

13 Solliance OPV Program Overview current status Presentation Introduction General Goal Current Status Way-of-Working Acknowledgements

module Efficiency Lifetime Cost Low water sensitive OPV stack design High end barrier &

14 Current status Solliance OPV 14 8,3% PCE certified & > 9% PCE non-certified polymer single junction cell 8,24% PCE polymer tandem cell 5,5% PCE certified polymer single junction module Efficiency Lifetime Cost Low water sensitive OPV stack design High end barrier & encapsulation (WVTR 10-6 g/day.m 2 ) Low-cost OPV modules Cost of Ownership and Life Cycle Analysis tool

15 15 Efficiency status Solliance OPV Inverted polymer single junction cell Certified cell performance PCE = 8,3% Hadipour et al., Adv. Energy Mater., 2011, XX, 1-6

16 16 Efficiency status Solliance OPV Inverted polymer single junction cell Further optimized cell design: not yet certified PCE > 9%

17 17 Efficiency status Solliance OPV Current Density (ma/cm 2 ) tandem experiment tandem simulation back cell exp front cell exp front cell simulation back cell simulation EQE ma/cm ma/cm 2 Tandem J sc Bias (V) V oc (V) FF PCE (ma cm 2 ) Simulated % 8.24% Experiment H 3 C C 8 H 17 C 6 H 13 O N S O PMDPP3T N S C 6 H 13 C 8 H 17 Wavelength (nm) CH 3 S S n S N N S PCDTBT C 8 H 17 C8 H 17 N n

18 Efficiency status Solliance OPV Certified OPV

1.43 11.4 55 5.0 16 IMEC encapsulated 6440 805 1.37 11.

18 18 Efficiency status Solliance OPV Certified OPV module efficiency Lab comment Voc (mv) Voc/8 (mv) Jsc (ma/cm2) Jsc*8 (ma/cm2) FF (%) Eff (%) aperture Aperture area (cm 2 ) IMEC after fabrication IMEC encapsulated Newport after 3 weeks % 15.6

Efficiency status Solliance OPV Semi-transparent OPV module efficiency 19 8*current density (ma/cm²) 16 12 8 4 0-4 -8-12 PV10 PAL2 full - full PV10 PAL2 semi - semi XPbing PAL1 - semi -16-250 0 250

19 Efficiency status Solliance OPV Semi-transparent OPV module efficiency 19 8*current density (ma/cm²) PV10 PAL2 full - full PV10 PAL2 semi - semi XPbing PAL1 - semi Voltage/8 (mv) Active layer Configuration full contact/ Voc (mv) Voc/8 (mv) Jsc Jsc*8 (ma/cm2) (ma/cm2) FF (%) aperture area: 16 cm 2 Eff (%) aperture PAL2 encapsulated PAL2 semi-transparent % PAL1 semi-transparent

impact of hygroscopic layers Girotto, C.

20 20 Lifetime status OPV Solliance Lifetime Slow down/inhibit degradation induced by ambient atmosphere conditions Reduce impact of hygroscopic layers Girotto, C. et al; AFM (2011); Voroshazi, E. et al; SEMSC (2011); Voroshazi, E. et al; OE (2011)

substrate & thin film encapsulation 1,2 1,0 WVTR 10-6 g/day.

21 21 Holst Centre barrier technology Performance in OLED Glass substrate & thin film encapsulation WVTR 10-6 g/day.m 2 OLEDs have passed 2500 hrs at 60 C/90%RH: no black spots 1 st gen barrier current barrier Performance in OPV Flexible barrier substrate & thin film encapsulation 1,2 1,0 WVTR 10-6 g/day.m 2 Similar stability to glass + metal cap 60 C/90%RH Normalized MMP 0,8 0,6 0,4 0,2 0,0 Barrier substrate & thin film encapsulation Glass substrate & metal lid encapsulation Time 1,5 AM & 45oC

22 Cost and upscaling status OPV Solliance Cost of Ownership calculations for R2R 250 MWp fab: Materials: 59% ITO Barrier Silver Scrap (yield): 34% Benchmark/Process

22 22 Cost and upscaling status OPV Solliance Cost of Ownership calculations for R2R 250 MWp fab: Materials: 59% ITO Barrier Silver Scrap (yield): 34% Benchmark/Process monitor Solution processed versus evaporated S2S versus R2R Tandem versus single junction 20 MWp fab versus 500 MWp fab Identification of low cost production scenario s

23 Cost and upscaling status OPV Solliance 23 $/Wp calculations for different OPV device designs and processes for 3 different cell efficiencies 1 PET + barrier + ITO 2 PET + barrier + Printed Ag grid + PEDOT 3 ITO + Ag grid 4 Metal foil + resist + Printed Ag grid + PEDOT 5a PET + barrier + Printed Cu grid + PEDOT 5b Metal foil + Resist + Printed Cu grid + PEDOT

barrier + Printed Ag grid + PEDOT 3 ITO + Ag grid 4 Metal foil + resist + Printed Ag grid

24 Cost and upscaling status OPV Solliance 24 $/Wp calculations for different OPV device designs and processes for 3 different cell efficiencies 1 PET + barrier + ITO 2 PET + barrier + Printed Ag grid + PEDOT 3 ITO + Ag grid 4 Metal foil + resist + Printed Ag grid + PEDOT 5a PET + barrier + Printed Cu grid + PEDOT 5b Metal foil + Resist + Printed Cu grid + PEDOT

25 Cost and upscaling status OPV Solliance 25 $/Wp calculations for different OPV device designs and processes for 3 different cell efficiencies 1 PET + barrier + ITO 2 PET + barrier + Printed Ag grid + PEDOT 3 ITO + Ag grid 4 Metal foil + resist + Printed Ag grid + PEDOT 5a PET + barrier + Printed Cu grid + PEDOT 5b Metal foil + Resist + Printed Cu grid + PEDOT

26 Cost and upscaling status OPV Solliance 26 $/Wp calculations for different OPV device designs and processes for 3 different cell efficiencies 1 PET + barrier + ITO 2 PET + barrier + Printed Ag grid + PEDOT 3 ITO + Ag grid 4 Metal foil + resist + Printed Ag grid + PEDOT 5a PET + barrier + Printed Cu grid + PEDOT 5b Metal foil + Resist + Printed Cu grid + PEDOT

27 Cost and upscaling status OPV Solliance 27 $/Wp calculations for different OPV device designs and processes for 3 different cell efficiencies 1 PET + barrier + ITO 2 PET + barrier + Printed Ag grid + PEDOT 3 ITO + Ag grid 4 Metal foil + resist + Printed Ag grid + PEDOT 5a PET + barrier + Printed Cu grid + PEDOT 5b Metal foil + Resist + Printed Cu grid + PEDOT

28 Cost and upscaling status OPV Solliance 28 $/Wp calculations for different OPV device designs and processes for 3 different cell efficiencies 0,5 USD/Wp seems to be feasible already at 12% cell efficiency (9,3 % total module efficiency) 1 PET + barrier + ITO 2 PET + barrier + Printed Ag grid + PEDOT 3 ITO + Ag grid 4 Metal foil + resist + Printed Ag grid + PEDOT 5a PET + barrier + Printed Cu grid + PEDOT 5b Metal foil + Resist + Printed Cu grid + PEDOT

Cost and upscaling status OPV Solliance Low-cost option:

deposition d(nm) evaporate 1/100 spin coat 150 spin coat 30

inverted PEDOT/inverted PEDOT/inverted solution processed

0 Voltage (V) 29 Reference: inverted design material

spin coat 30 sputter 123 All-solution processed material

29 Cost and upscaling status OPV Solliance Low-cost option: material All-Solution Processed Reference: standard design deposition d(nm) evaporate 1/100 spin coat 150 spin coat 30 sputter 123 Current Density (ma/cm 2 ) standard inverted PEDOT/inverted PEDOT/inverted solution processed P3HT/PCBM Voltage (V) 29 Reference: inverted design material deposition d(nm) evaporate 100 spin coat 180 spin coat 250 spin coat 30 sputter 123 All-solution processed material deposition d(nm) screen pr spin coat 1000 spin coat 260 spin coat 30 ink jet 70 ink jet 500 Introducing Scalable Processes

30 30 Upscaling status OPV Solliance Printing: ink jet, (rotary) screen printing of metal grids Low sheet resistance ( 1 Ohm/Sq) with low surface coverage ( 5%) possible Sintering is typical a thermal process Furnace For 10 m/min, 400 meter furnace required Faster sintering technologies are required: photonic sintering Example: rotary screen printing (SPG Prints Module) and sintering 5 m/min Thermal sintering (110 o C) Resistance (Ω) Photonic sintering (750 W) time (min) SunTronic U5603 Ag nanoparticle ink

S2S R2R (choice is CoO and application related) Upscaling status Solliance OPV Slot die together with ntact: R2R intermittent stripe coating Slot Die, Spray Coating, Ink Jet (choice is CoO and

31 S2S R2R (choice is CoO and application related) Upscaling status Solliance OPV Slot die together with ntact: R2R intermittent stripe coating Slot Die, Spray Coating, Ink Jet (choice is CoO and application related) Coatema/Troller/nTact 30 cm modular R2R coat and print line R2R 30 cm ink jet modules 31 ntact (partner) S2S intermittent slot die with shims Direct coating of squares or rectangles Spray Coater Sonotek OTB Solar/MiPlaza S2S 6 inch ink jet engine with integrated dryer

32 Upscaling status Solliance OPV Example: patterned R2R slot die coating of P3HT/PCBM Ink formulation developed for ink jet printing on HC-PEDOT Three (non-chlorinated) solvents system Only stable enough at elevated temperature (40 50 C) Heated slot die Layer uniformity Critical for multi-solvent system: unwanted Marangoni flows High end dry process needed 32 Drying process 1 Drying process 2 Improved edge control with special designed slot die by ntact

33 Upscaling status Solliance OPV Ink Jet Printing of PAL (P3HT (Merck)/PCBM) 33 IJP halogen free 3 solvent system vs SC chlorobenzene 20 dark X 15 solvent IXT ref cell SC 10 5 LP50 Ink Jet Printer OTB/Roth&Rau bias (V) I (ma/cm 2 ) V oc (V) I sc (ma/cm 2 ) FF (%) Ink Jet Printed 3 solvent system X Konica Minolta head 512 nozzles MPP (mw/cm 2 ) 2 cm x 2 cm single pass Spin Coated Chlorobenzene

34 Upscaling status Solliance OPV Spray coating Implement spray coating in our module process - Spin or sprayed + photo-active P3HT:PCBM layer Area Eff Jsc FF Voc [cm²] [%] [ma/cm²] [%] [mv] Very

34 34 Upscaling status Solliance OPV Spray coating Implement spray coating in our module process - Spin or sprayed + photo-active P3HT:PCBM layer Area Eff Jsc FF Voc [cm²] [%] [ma/cm²] [%] [mv] Very small (±0.1) 9.3 (±0.3) 64 (±1.0) 585 (±2.7) Small (±0.1) 9.2 (±0.1) 63 (±1.9) 584 (±3.3) Medium Large (spin) Large (spray)

cells P3 P2 P1 Ag ~ 150 nm* P3HT/PCBM ~ 250 nm* ZnO ~ 30 nm* ITO~

35 35 Upscaling status Solliance OPV: Laser ablation On glass and with ITO 2% efficient modules of 4x4 cm 2 on glass/ito with 8 cells P3 P2 P1 Ag ~ 150 nm* P3HT/PCBM ~ 250 nm* ZnO ~ 30 nm* ITO~ 100 nm* * Layer deposition +/- 10 nm offset P1 P1 P2 P1 P2 73 µm 83 µm P3

36 36 Upscaling status Solliance OPV: Laser ablation On PET and with printed Ag-grid + printed HC-PEDOT P1 180 nm 120 nm 300 nm P2 PAL PEDOT Ag Iso PAL PEDOT Ag PET PET Step 1: Selective laser scribing of P1&P2 Step 2: P1 filling with ISO P1 P2 PET PAL PEDOT Ag Step 3: Cathode evaporation

37 37 Upscaling status Solliance OPV: Laser ablation On PET and with printed Ag-grid + printed HC-PEDOT P1 180 nm 120 nm 300 nm P2 PAL PEDOT Ag Iso PAL PEDOT Ag PET PET Step 1: Selective laser scribing of P1&P2 Step 2: P1 filling with ISO P1 P2 PET PAL PEDOT Ag Step 3: Cathode evaporation

38 38 Upscaling status Solliance OPV: Laser ablation On PET and with printed Ag-grid + printed HC-PEDOT P1 180 nm 120 nm 300 nm P2 PAL PEDOT Ag Iso PAL PEDOT Ag PET PET Step 1: Selective laser scribing of P1&P2 Step 2: P1 filling with ISO P1 P2 PET PAL PEDOT Ag Step 3: Cathode evaporation

39 39 Upscaling status Solliance OPV: Laser ablation On PET and with printed Ag-grid + printed HC-PEDOT P1 180 nm 120 nm 300 nm P2 PAL PEDOT Ag Iso PAL PEDOT Ag PET PET Step 1: Selective laser scribing of P1&P2 Step 2: P1 filling with ISO P1 P2 PET PAL PEDOT Ag Step 3: Cathode evaporation

Ag Iso PAL PEDOT Ag PET PET Step 1: Selective laser scribing of P1&P2

40 40 Upscaling status Solliance OPV: Laser ablation On PET and with printed Ag-grid + printed HC-PEDOT P1 180 nm 120 nm 300 nm P2 PAL PEDOT Ag Iso PAL PEDOT Ag PET PET Step 1: Selective laser scribing of P1&P2 Step 2: P1 filling with ISO P1 P2 PET PAL PEDOT Ag Step 3: Cathode evaporation

41 41 Upscaling status Solliance OPV: Barrier Current S2S status: WVTR 10-6 g/day.m 2 Current R2R status: R2R tool developed and built by and Roth & Rau

42 Solliance OPV Program Way-of-Working Presentation Introduction General Goal Current Status Way-of-Working Acknowledgements

43 How is the R&D program organized? 43 WP1 WP2 WP3 WP5 WP4

industrial partners have entered the Solliance OPV program and Several explorative industrial

44 44 Solliance OPV: together in Shared Research Shared research has a high level of risk leverage All companies belonging to the value chain of OPV are needed in order to bring OPV to a real success First industrial partners have entered the Solliance OPV program and Several explorative industrial collaborations are running Material Suppliers SF- Products Suppliers Equipment Suppliers Manufacturers End-users

45 45 Solliance OPV: together in Shared Research Open invitation for open innovation Industrial value chain still needs to be further completed OPV is very complex, hence Material Suppliers SF- Products Suppliers Equipment Suppliers Manufacturers End-users Are you the next to join our initiative?

46 Solliance OPV Program Acknowledgements Presentation Introduction General Goal Current Status Way-of-Working Acknowledgements

47 47 Acknowledgements Yulia Galagan, Nadia Grossiord, Jürgen Sweelssens, Moa Ren, Date Moet, Jan Gilot, Ike De Vries, Arjan Langen, Eric-Jan Rubingh, Tim Van Lammeren, Francois Furthner, Bérenger Roth, Prof. Paul Blom, Jan Kroon, Sjoerd Veenstra, Wiljan Verhees, Tristram Budel, Lenneke Slooff, Birger Zimmermann, Dirk Bollen, Prof. René Janssen, Tom Aernouts, Afshin Hadipour, Eszter Voroshazi, Griet Uytterhoeven, Prof. Paul Heremans, OZOFAB

48 Solliance OPV your Opportunity in a Partnership with Vision Thank you for your attention! Ronn Andriessen Program Manager ronn.andriessen@tno.nl

49 Visit the Solliance booth Hall 3.0/F12 Visit the imec booth Hall 3.1/C7 Visit the ECN booth Hall 3.1/F14

Printable Organic Solar Cells Challenges and Opportunities in Technology Transfer from Lab to Market

Power Plastic R Printable Organic Solar Cells Challenges and Opportunities in Technology Transfer from Lab to Market Alan J. Heeger Chief Scientist and Co-Founder 116 John Street, Lowell, MA 01852 Plastic