All solution processing of ITO-free organic solar cell modules directly on barrier foil

In this study, we demonstrate fully solution processed semi-transparent silver electrodes on flexible substrates having a sheet resistance as low as 5 Ω/□ and transmittance of ∼30% at 550 nm. We demonstrate the use of this electrode as a substitute for ITO in an inverted organic solar cell (OSC) with the layer sequence, PET/Ag/ZnO/P3HT:PCBM/PEDOT:PSS/Ag where illumination is achieved through the first Ag layer. Power conversion efficiency of up to 1.6% under 1 sun illumination (100 mW cm−2 and AM1.5G) is achieved for small area (1 cm2) test devices. We further demonstrate scalability of the semi-transparent Ag electrode fabrication in a roll-to-roll (R2R) process using slot-die coating. This electrode is further utilized in R2R processing of large area modules (active area 35.5 cm2) where all layers in the modules are R2R processed with solution-based materials in ambient conditions without any use of vacuum steps. We further demonstrate the possibility of using barrier foil as the substrate in the R2R processing of modules. Module performance is evaluated by current–voltage characterization and Light Beam Induced Current (LBIC imaging). Such a semi-transparent Ag electrode incurs very little material and processing cost and is a cost-effective alternative to ITO for low-cost organic solar cells.

Graphical AbstractFigure optionsDownload full-size imageDownload as PowerPoint slideHighlights► Processing of polymer solar cells directly on barrier foil enabled thinner solar cells. ► Less adhesive and less process steps was found beneficial. ► Thin outline and ITO-freedom was found to yield robust modules. ► Slot-die coating of thin silver precursor films gave semitransparent and conductive electrodes.