High precision processing of flexible P3HT/PCBM modules with geometric fill factor over 95%

• We present high precision production process of flexible P3HT:PCBM OPV modules with an PCE above 3% and GFF above 95%.
• We combined the slot-die coating and high resolution laser patterning.
• Demonstrated fabrication procedure is roll-to-roll compatible.
• We demonstrate flexible modules showing identical performance to optimized small scale lab devices.
• Devices withstand 1000s of bending cycles.

Flexible OPV modules, based on P3HT:PCBM as absorber layer, were manufactured with a power conversion efficiency over 3% and for a total area of 3500 mm2 consisting of 14 in series interconnected cells. The modules utilize the excellent mechanical and the outstanding optical properties of sputtered transparent ITO-Metal-ITO (IMI) electrodes deposited on the PET foil on the one hand, and the combination of large area slot-die coating with high resolution ultrafast laser patterning on the other hand. The manufacturing of modules with outstanding performance was found to be reproducible. The right combination of innovative electrodes and smart roll-to-roll compatible processing technologies demonstrates a viable path towards high efficient industrial module technology.

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