Manufacturing high efficiency physically robust flexible OSC modules with long lifetimes

In direct support of the research problem of the STTR 2021.A Organic Solar Cell Processing and Product Development topic, the main technical objectives are to develop a prototype flexible >50 cm2 OPV module with >11% performance and a geometric fill factor >90%. Furthermore, these modules are to be fabricated with scalable methods such as slot die coating on ITO coated PET substrates. The intrinsic stability of the tailored and stabilized active layer, enhanced by an encapsulation barrier, will provide a module lifetime of >5 years with intermittent light exposure corresponding to 0.1-0.5 sun-years. Module lifetime will be evaluated by mechanical stress tests, repeated extreme temperature cycling (20 °C - 110 °C), and high light intensity testing with up to 80 suns. The targeted fabrication yield is >90% and modules will be impact-resistant to hail (following ASTME E1038-10). The fundamental and applied knowledge to achieve these objectives will be researched and developed, and will comprise accelerated light stability testing, mechanical characterization, and electrical testing. The active layer donor polymer will include PTQ10, due to attractive cost and processing characteristics. Packaging with favorable W/kg, W/volume and $/W capacity (Wp) will be targeted. The business model will be developed, including product concepts for military and recreational applications, and cost analysis for appropriate markets. Partnerships for scaled-up product and field tests will be sought. These technical goals represent significant advances over phase I results that achieved a three-cell mini-modules with 3 cm2 total device area and 11% performance on rigid substrates utilizing blade-coating, with individual spin-coated 1 cm2 cells achieving >13% efficiency.