Towards large-scale production of solution-processed organic tandem modules based on ternary composites: Design of the intermediate layer, device optimization and laser based module processing

•An efficient solution-processed intermediate layer for organic tandem solar cells.•This intermediate layer shows promising functionality without thermal treatment.•Ternary concept is used in tandem structure to enhance the device performance.•Laser-patterning is used to fabricated the lab-scale organic tandem modules.•Geometrical fill factor of ~85% is achieved for the 10-cell tandem modules.

We report on a novel approach including: 1. the design of an efficient intermediate layer, which facilitates the use of most high performance active materials in tandem structure and the compatibility of the tandem concept with large-scale production; 2. the concept of ternary composites based on commercially available materials, which enhances the absorption of poly(3-hexylthiophene) (P3HT) and as a result increase the PCE of the P3HT-based large-scale OPV devices; 3. laser-based module processing, which provides an excellent processing resolution and as a result can bring the power conversion efficiency (PCE) of mass-produced organic photovoltaic (OPV) devices close to the highest PCE values achieved for lab-scale solar cells through a significant increase in the geometrical fill factor. We believe that the combination of the above mentioned concepts provides a clear roadmap to push OPV towards large-scale production and commercial applications.

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