Upscaling of polymer solar cell fabrication using full roll-to-roll processing
Upscaling of polymer solar cell fabrication using full roll-to-roll processing
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DOI：
10.1039/b9nr00430k
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发表时间：
2010-01-01
期刊：
影响因子：
6.7
通讯作者：
Jorgensen, Mikkel
中科院分区：
文献类型：
--
作者：
Krebs, Frederik C.;Tromholt, Thomas;Jorgensen, Mikkel
详细介绍了聚合物太阳能电池制造的升级，重点是成本分析和实用方法。使用狭缝模头涂布和丝网印刷串联连接的条带形式的活性层来制备器件模块。改变条纹宽度并分析所得性能。更宽的条纹提供更高的几何填充因子和更低的孔径损耗，同时它们也呈现更大的薄层电阻损耗。通过制备宽度为9、13和18 mm、标称几何填充因子（不包括汇流条）分别为50、67和75%的串联条带，找到了最佳方案。此外，还探索了长度为6、10、20、22.5和25 cm的模块。该装置是通过全卷对卷溶液处理制备的，幅材宽度为305 mm，卷长达200 m。这些器件采用标准粘合剂在完整的卷对卷工艺中用阻隔材料封装，使器件在储存和操作期间具有优异的稳定性。加工的聚合物太阳能电池的总面积为每次运行约60 m2。使用包括太阳能模拟器和IV曲线追踪器的卷对卷系统对太阳能电池进行了表征。在表征之后，使用压片机将太阳能电池模块切成片，并使用通过压接施加的按钮触点进行接触。在此基础上进行了详细的成本分析，表明可以以89（sic）m2（-2）的面积成本和8.1（sic）W（p）（-1）的电力成本制备这种规模的完整和接触的聚合物太阳能电池模块。成本分析分为制造成本、材料成本以及建立这种规模的完整生产工厂所需的资本投资。尽管W（p）（-1）的成本与使用现有技术的电力成本相当，但由于使用寿命较短，预计平准化电力成本将大大高于现有技术。因此，所提出的设备对于消费电子产品是有竞争力的，但不适合以其当前形式的并网电力生产。
Upscaling of the manufacture of polymer solar cells is detailed with emphasis on cost analysis and practical approach. The device modules were prepared using both slot-die coating and screen printing the active layers in the form of stripes that were serially connected. The stripe width was varied and the resultant performance analysed. Wider stripes give access to higher geometric fill factors and lower aperture loss while they also present larger sheet resistive losses. An optimum was found through preparation of serially connected stripes having widths of 9, 13 and 18 mm with nominal geometric fill factors (excluding bus bars) of 50, 67 and 75% respectively. In addition modules with lengths of 6, 10, 20, 22.5 and 25 cm were explored. The devices were prepared by full roll-to-roll solution processing in a web width of 305 mm and roll lengths of up to 200 m. The devices were encapsulated with a barrier material in a full roll-to-roll process using standard adhesives giving the devices excellent stability during storage and operation. The total area of processed polymer solar cell was around 60 m(2) per run. The solar cells were characterised using a roll-to-roll system comprising a solar simulator and an IV-curve tracer. After characterisation the solar cell modules were cut into sheets using a sheeting machine and contacted using button contacts applied by crimping. Based on this a detailed cost analysis was made showing that it is possible to prepare complete and contacted polymer solar cell modules on this scale at an area cost of 89 (sic) m(-2) and an electricity cost of 8.1 (sic) W(p)(-1). The cost analysis was separated into the manufacturing cost, materials cost and also the capital investment required for setting up a complete production plant on this scale. Even though the cost in (sic) W(p)(-1) is comparable to the cost for electricity using existing technologies the levelized cost of electricity (LCOE) is expected to be significantly higher than the existing technologies due to the inferior operational lifetime. The presented devices are thus competitive for consumer electronics but ill-suited for on-grid electricity production in their current form.