Upscaling of polymer solar cell fabrication using full roll-to-roll processing

Area of Science:

• Materials Science
• Renewable Energy Engineering
• Manufacturing Technology

Background:

• Polymer solar cells (PSCs) offer potential for flexible and low-cost energy generation.
• Scaling up PSC manufacturing from lab to industrial levels presents significant challenges in cost, efficiency, and stability.
• Roll-to-roll (R2R) processing is a key technology for high-throughput, cost-effective PSC production.

Purpose of the Study:

• To investigate the upscaling of polymer solar cell (PSC) manufacturing using roll-to-roll (R2R) solution processing.
• To perform a detailed cost analysis of the scaled-up PSC production process.
• To evaluate the suitability of the manufactured PSCs for different applications based on performance and cost.

Main Methods:

• Device fabrication via slot-die coating and screen printing of active layer stripes on a 305 mm web width.
• Optimization of stripe width and module length for geometric fill factor and performance.
• Full R2R encapsulation using barrier materials and standard adhesives.
• Characterization using an integrated R2R solar simulator and IV-curve tracer.
• Detailed cost breakdown including manufacturing, materials, and capital investment.

Main Results:

• Achieved scalable R2R production of PSC modules up to 200 m roll lengths, processing approximately 60 m² per run.
• Identified optimal stripe widths (9-18 mm) balancing geometric fill factor and resistive losses.
• Demonstrated stable PSCs with excellent storage and operational stability.
• Attained an area cost of 89 €/m² and an electricity cost of 8.1 €/Wp.
• Cost analysis separated into manufacturing, materials, and capital investment.

Conclusions:

• R2R solution processing enables cost-effective upscaling of PSC manufacturing.
• The achieved production costs make PSCs competitive for consumer electronics applications.
• The current operational lifetime of the PSCs is insufficient for on-grid electricity production, necessitating further improvements.
• Further research is required to enhance device longevity for grid-scale energy generation.