PE 2012 - Solliance OPV Program - Ronn Andriessensemieurope.omnibooksonline.com/2012/semicon_europa/Plastic... · 3 PE 2012 - Solliance OPV Program - Ronn Andriessen Solliance partners

SOLLIANCEA R&D cluster bringingthin film solar energy technologyto excellence

Solliance OPV: Towards Low Cost, Efficient and Stable OrganicPhotovoltaic Modules

Ronn Andriessen

Solliance OPV Program

Introduction Presentation

• Introduction• General Goal• Current Status• Way-of-Working• Acknowledgements

3

PE 2012 - Solliance OPV Program - Ronn Andriessen

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


A. Transparent Conductive Layers

B. Barriers and Encapsulation

C. Interconnection

D. Light Management

E. Manufacturing Technologies: Vacuum

F. Manufacturing Technologies: Wet Chemical

H. Modules & Integration

I. Equipment Design & Engineering

G. Modeling & Characterisation

2. TF-CIGS

3. TF-OPV

1. TF-Si

Shared Research Centre on Thin Film PV

3 thin film PV technologies connected by Generic enabling technologies

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


Impression new Solliance building @ HTC

Expected Q2 2013


General Goal Presentation


8


Working principle OPV: Bulk Heterojunction

OMe

O

OMe

O

(

)n

e-

MDMO-PPV PCBMas donor (D) as acceptor (A)

N.S. Sariciftci et al., Science, 1992, 258, 1474C.J. Brabec et al., Chem. Phys. Lett, 2001, 340(3,4), 232

45 fs

Recombination: from µs to ms

D

A

-

metal top electrode

transparent bottom electrodeglass

The donor and acceptor are nanoscopicallymixed to overcome ~10 nm exciton diffusion length and increase donor/acceptor interface.

Light

R. H. Friend et al., Nature, 1995, 376, 498 A. J. Heeger et al., Science, 1995, 270, 1789

D

A

9


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)

• By operating under the open innovation model i.e. shared research together with companies belonging to the

value chain of OPV

Efficiency

CostLifetime


10


Performance, lifetime & Processing Roadmap

EL

EL

ELC

11


Solliance Technology Roadmap for OPV

OPV now:

~ 10 €/Wp (~ 150 €/m2) 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 now:

~ 10 €/Wp (~ 150 €/m2) 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 1000 hrs @

65°C/45% RH, 1 sun

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 1000 hrs @

65°C/45% RH, 1 sun

12


New planned OPV facilitiesR2R up to 30 cm width

20 m 16,5 m

No clean room Clean room

20 m

4 m

2,40 m

Deposition

Roll-on

Roll-offCleaning

&Alignment

Post cureInspection

&Alignment

1,20 m

1,20 m

4 m

DryerModule x (DMx)

1,5–2 m

DM1DM2DM3DM4DM5DM6DM7DM8

Foil U-turner

DM1DM2DM3DM4

DM1DM2DM3DM4

R2Rline 1

R2Rline 3

R2Rline 2

R2R metal

R2R lamination

R2R nanoimprint

1,20 m

Eindhoven to be re-integrated and extended

Minimum need for clean room

For OPV but also for other thin film PV like e.g. CIGSbut also forOLED

Easy extensible


Overview current status Presentation


14


Current status Solliance OPV

Efficiency

CostLifetime

• 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

• 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


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



Inverted polymer single junction cell• Further optimized cell design: not yet certified

PCE > 9%

17



N

N

O

O

SS

C6H13

C8H17

C6H13C8H17

n

S

PMDPP3T

H3C

CH3

N

SN

S S

N

C8H17 C8H17

n

PCDTBT

Tandem Jsc

(mA cm −2)

Voc (V) FF PCE

Simulated 9.5 1.47 0.59 8.25%

Experiment 9.6 1.46 0.59 8.24

-1.0 -0.5 0.0 0.5 1.0 1.5-12

-10

-8

-6

-4

-2

0

2

Cur

rent

Den

sity

(m

A/c

m2 )

Bias (V)

tandem experiment tandem simulation back cell exp front cell exp front cell simulation back cell simulation

300 400 500 600 700 800 900 1000 11000.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7 9.22 mA/cm2

9.72 mA/cm2

EQ

E

Wavelength (nm)

8.24%

18


Efficiency status Solliance OPV Certified OPV module efficiency

Lab commentVoc (mV)

Voc/8 (mV)

Jsc(mA/cm2)

Jsc*8 (mA/cm2)

FF (%)Eff (%)

aperture

Aperture

area (cm2)

IMEC after fabrication 6400 800 1.43 11.4 55 5.0 16

IMEC encapsulated 6440 805 1.37 11.0 58 5.1 16

Newport after 3 weeks 6648 831 1.25 10.0 66 5.5 15.65.5%

19



Active layer Configuration

Voc (mV)

Voc/8 (mV)

Jsc(mA/cm2)

Jsc*8 (mA/cm2) FF (%)

Eff (%)aperture

PAL2full contact/

encapsulated 5880 735 1.42 11.4 63 5.2PAL2 semi-transparent 6270 784 1.18 9.4 67 5.0PAL1 semi-transparent 5520 690 1.01 8.1 49 2.8

aperture area: 16 cm2

Semi-transparent OPV module efficiency

5.0%

-250 0 250 500 750 1000-16

-12

-8

-4

0

4

8

12

16

PV10 full PV10 semi XPbing semi

8*cu

rren

t den

sity

(m

A/c

m²)

Voltage/8 (mV)

PAL2 - fullPAL2 - semiPAL1 - semi

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)

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

Performance in OPV• Flexible barrier substrate &

thin film encapsulation• WVTR 10-6 g/day.m 2

• Similar stability to glass + metal cap

0,0

0,2

0,4

0,6

0,8

1,0

1,2

0 200 400 600 800 1000 1200

Time [hours] @ 1,5 AM & 45oC

Nor

mal

ized

MM

P

Glass substrate & metal lid encapsulation

Barrier substrate & thin film encapsulation

1st gen barrier current barrier

Age

ing

@ 6

0°C

/90%

RH

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


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 $/Wp calculations for different OPV device designs

and processes for 3 different cell efficiencies

24




3 ITO + Ag grid






25




3 ITO + Ag grid






26




3 ITO + Ag grid






27




3 ITO + Ag grid






28




3 ITO + Ag grid






0,5 USD/Wp seems to be feasible already at

12% cell efficiency (9,3 % total module

efficiency)

0,5 USD/Wp seems to be feasible already at

12% cell efficiency (9,3 % total module

efficiency)

29


Cost and upscaling status OPV Solliance Low-cost option:

All-Solution Processed

sputter 123

evaporate 1/100

spin coat 150

spin coat 30

sputter 123

evaporate 100

spin coat 180

spin coat 250

spin coat 30

deposition d(nm)material


ink jet 500

screen pr. 17000

spin coat 1000

spin coat 260

spin coat 30

ink jet 70


Reference: standard design

Reference: inverted design All-solution processed

-10

-5

0

5

10

-0.5 0.0 0.5 1.0

Voltage (V)Cur

rent

Den

sity

(m

A/c

m2 ) standard

inverted PEDOT/inverted PEDOT/inverted solution processed

IntroducingScalableProcesses

P3HT/PCBM

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 R2R @ 10 m/min, 400 meter furnace required• Faster sintering technologies are required: photonic sintering• Example: rotary screen printing (SPG Prints Module) and sintering in-line @ 5 m/min

• http://www.youtube.com/watch?v=7SpZPIVtryM

0 2 4 6 8 10100

102

104

106

108

Res

ista

nce

(Ω)

time (min)

Thermal sintering (110 oC)

Photonic sintering (750 W)

SunTronic U5603 Ag nanoparticle ink

31


Slot die together with nTact: R2R intermittent stripe coating

OTB Solar/MiPlazaS2S 6 inch ink jet engine with integrated dryer

nTact (partner)S2S intermittent slot die with shimsDirect coating of squares or rectangles

R2R 30 cm ink jet modules

S2S

R

2R (c

hoic

e is

CoO

and

appl

icat

ion

rela

ted)

Coatema/Troller/nTact30 cm modular R2R coat and print line

Upscaling status Solliance OPV

Spray CoaterSonotek

Slot Die, Spray Coating, Ink Jet (choice is CoO and application related)

32


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

Drying process 1 Drying process 2


Improved edge control with special designed slot die by nTact

33


Ink Jet Printing of PAL (P3HT (Merck)/PCBM)

-20

-15

-10

-5

0

5

10

15

20

-2 -1 0 1bias (V)

I (mA/cm2)

IJP halogen free 3 solvent system vs SC chlorobenzene

dark

solvent IXT

ref cell SC

X


Voc(V)

Isc(mA/cm 2)

FF(%)

MPP(mW/cm 2)

Ink Jet Printed 3 solvent system X 0.58 10.62 52 3.19

Spin Coated Chlorobenzene 0.55 11.97 48 3.13

2 cm x 2 cm single pass

Konica Minolta head512 nozzles

LP50Ink Jet PrinterOTB/Roth&Rau

34



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 0.031 3.5 (±0.1) 9.3 (±0.3) 64 (±1.0) 585 (±2.7)

Small 0.134 3.4 (±0.1) 9.2 (±0.1) 63 (±1.9) 584 (±3.3)

Medium 1.33 2.9 1.5 59 3390

Large (spin) 13.9 2.4 1.1 50 4430

Large (spray) 15.8 2.5 1.0 54 4690

35


Upscaling status Solliance OPV: L aser ablation

P3P3HT/PCBM ~ 250 nm*

ZnO ~ 30 nm*

ITO~ 100 nm*

Ag ~ 150 nm*

* Layer deposition +/- 10 nm offset

P2P1

On glass and with ITO• 2% efficient modules of 4x4 cm2 on glass/ITO with 8 cells

P1P1 P2P2P1 P2P1P1

P2P2

P3P3

73 µm73 µm

83 µm83 µm

P1

P2

P3

73 µm

83 µm

P1

36


Upscaling status Solliance OPV: Laser ablation

On PET and with printed Ag-grid + printed HC-PEDOT

PEDOTPAL

Ag

PET

P1 P2

Step 1: Selective laser scribing of P1&P2

120 nm

300 nm

180 nm

PEDOTPAL

Ag

PET

Iso

Step 2: P1 filling with ISO

PEDOTPAL

Ag

PET

P1 P2

Step 3: Cathode evaporation

37




PEDOTPAL

Ag

PET

P1 P2


120 nm

300 nm

180 nm

PEDOTPAL

Ag

PET

Iso


PEDOTPAL

Ag

PET

P1 P2


38




PEDOTPAL

Ag

PET

P1 P2


120 nm

300 nm

180 nm

PEDOTPAL

Ag

PET

Iso


PEDOTPAL

Ag

PET

P1 P2


39




PEDOTPAL

Ag

PET

P1 P2


120 nm

300 nm

180 nm

PEDOTPAL

Ag

PET

Iso


PEDOTPAL

Ag

PET

P1 P2


40




PEDOTPAL

Ag

PET

P1 P2


120 nm

300 nm

180 nm

PEDOTPAL

Ag

PET

Iso


PEDOTPAL

Ag

PET

P1 P2


41


Upscaling status Solliance OPV: Barrier

Current S2S status: • WVTR ≤ 10-6 g/day.m2

Current R2R status: • R2R tool developed and built by and Roth & Rau


Way-of-Working Presentation


43


WP1WP2

WP3

WP4WP5

How is the R&D program organized?

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

Manufac-

turersEnd-users

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

Manufac-

turersEnd-users

Are you the next to join our initiative?Are you the next to join our initiative?


Acknowledgements Presentation


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, WiljanVerhees, Tristram Budel, LennekeSlooff, Birger Zimmermann, Dirk Bollen, Prof. René Janssen, Tom Aernouts, Afshin Hadipour, Eszter Voroshazi, Griet Uytterhoeven, Prof. Paul Heremans, …

…

OZOFAB

WWW.SOLLIANCE.EU

Solliance OPVyour Opportunity in a Partnership with Vision

Ronn AndriessenProgram Manager+31 40 40 20 [email protected]

www.solliance.eu

Thank you for your attention!

Visit the Solliance booth Hall 3.0/F12Visit the imec booth Hall 3.1/C7Visit the ECN booth Hall 3.1/F14

Documents

PE 2012 - Solliance OPV Program - Ronn Andriessensemieurope.omnibooksonline.com/2012/semicon_europa/Plastic... · 3 PE 2012 - Solliance OPV Program - Ronn Andriessen Solliance partners