Fabrication and Scale-up of High Performance Low Band-gap Polymer Solar Cells by Spray-coating in Air
David Lidzey a, Nicholas Scarratt a, Jonathan Griffin a, Tao Wang a, Hunan Yi b, Ahmed Iraqi b, James Kingsley c
a Department of Physics and Astronomy, University of Sheffield, UK, Hounsfield Road, United Kingdom
b Department of Chemistry, University of Sheffield, Robert Dainton Building, Hounsfield Road, Sheffield, S3 7RH, United Kingdom
c Ossila Ltd, Kroto Innovation Centre, Broad lane, Sheffield, United Kingdom
International Conference on Hybrid and Organic Photovoltaics
Proceedings of 6th International Conference on Hybrid and Organic Photovoltaics (HOPV14)
Ecublens, Switzerland, 2014 May 11th - 14th
Organizers: Michael Graetzel and Mohammad Nazeeruddin
Poster, Nicholas Scarratt, 192
Publication date: 1st March 2014

In this work we present an ultrasonic spray coating technique which is capable of being scaled up for large area device fabrication and roll-to-roll processing. This technique was used in ambient conditions to deposit a photoactive blend consisting of carbazole and benzothiadiazole based low energy gap copolymers and the fullerene derivative [6,6]-Phenyl-C71-butyric acid methyl ester (PC70BM). Using a range of spray speeds, casting solvents and substrate temperatures we have been able to control film thickness and drying kinetics. Film characterization using atomic force microscopy and optical interferometry shows that spray-cast films have a comparable surface to spin-cast films.

By employing a novel solvent cleaning technique, the frequency of defects in spray-coated polymer blend films was reduced.  A high-resolution light beam induced current (LBIC) technique has been used to quantify the effects of these defects on current production in organic solar cells. A power conversion efficiency of 5.7% was obtained for solar cells with PCDTBT:PC70BM films cast from the cleaned solvent.

We have explored the scale-up of photovoltaic devices using spray-coating, and have conducted film depositions and device studies on a range of different substrate sizes and architectures. These include a 36 x 36 array of 6.5mm2 pixels, which we compare with a single pixel of 900mm2. We use such techniques to comment on the yield and efficiency of device scale-up.



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