Fabrication and processing of polymer solar cells: A review of printing and coating techniques

Following the development of the bulk heterojunction1 structure, recent years have seen a dramatic improvement in the efficiency of polymer solar cells. Maximizing the open-circuit voltage in a low-bandgap polymer is one of the critical factors towards enabling high-efficiency solar cells. Study of the relation between open-circuit voltage and the energy levels of the donor/acceptor2 in bulk heterojunction polymer solar cells has stimulated interest in modifying the open-circuit voltage by tuning the energy levels of polymers3. Here, we show that the open-circuit voltage of polymer solar cells constructed based on the structure of a low-bandgap polymer, PBDTTT4, can be tuned, step by step, using different functional groups, to achieve values as high as 0.76 V. This increased open-circuit voltage combined with a high short-circuit current density results in a polymer solar cell with a power conversion efficiency as high as 6.77%, as certified by the National Renewable Energy Laboratory. Adding electron-withdrawing groups to the backbone of the polymer PBDTTT is shown to increase the open-circuit voltage of photovoltaic cells, resulting in a polymer solar-cell that has a certified power-conversion efficiency of 6.77%.

/pdf/polymer-solar-cells-with-enhanced-open-circuit-voltage-and-464500qqzd.pdf

Polymer solar cells with enhanced open-circuit voltage and efficiency

Flexible electronics offer a wide-variety of applications such as flexible circuits, flexible displays, flexible solar cells, skin-like pressure sensors, and conformable RFID tags. Carbon nanotubes (CNTs) are a promising material for flexible electronics, both as the channel material in field-effect transistors (FETs) and as transparent electrodes, due to their high intrinsic carrier mobility, conductivity, and mechanical flexibility. In this feature article, we review the recent progress of CNTs in flexible electronics by describing both the processing and the applications of CNT-based flexible devices. To employ CNTs as the channel material in FETs, single-walled carbon nanotubes (SWNTs) are used. There are generally two methods of depositing SWNTs on flexible substrates—transferring CVD-grown SWNTs or solution-depositing SWNTs. Since CVD-grown SWNTs can be highly aligned, they often outperform solution-processed SWNT films that are typically in the form of random network. However, solution-based SWNTs can be printed at a large-scale and at low-cost, rendering them more appropriate for manufacturing. In either case, the removal of metallic SWNTs in an effective and a scalable manner is critical, which must still be developed and optimized. Nevertheless, promising results demonstrating SWNT-based flexible circuits, displays, RF-devices, and biochemical sensors have been reported by various research groups, proving insight into the exciting possibilities of SWNT-based FETs. In using carbon nanotubes as transparent electrodes (TEs), two main strategies have been implemented to fabricate highly conductive, transparent, and mechanically compliant films—superaligned films of CNTs drawn from vertically grown CNT forests using the “dry-drawing” technique and the deposition or embedding of CNTs onto flexible or stretchable substrates. The main challenge for CNT based TEs is to fabricate films that are both highly conductive and transparent. These CNT based TEs have been used in stretchable and flexible pressure, strain, and chemical and biological sensors. In addition, they have also been used as the anode and cathode in flexible light emitting diodes, solar cells, and supercapacitors. In summary, there are a number of challenges yet to overcome to optimize the processing and performance of CNT-based flexible electronics; nonetheless, CNTs remain a highly suitable candidate for various flexible electronic applications in the near future.

A review of fabrication and applications of carbon nanotube film-based flexible electronics

Highly conductive and transparent poly-(3,4-ethylenedioxythiophene):poly(styrenesulfonic acid) (PEDOT:PSS) films, incorporating a fluorosurfactant as an additive, have been prepared for stretchable and transparent electrodes. The fluorosurfactant-treated PEDOT:PSS films show a 35% improvement in sheet resistance (Rs) compared to untreated films. In addition, the fluorosurfactant renders PEDOT:PSS solutions amenable for deposition on hydrophobic surfaces, including pre-deposited, annealed films of PEDOT:PSS (enabling the deposition of thick, highly conductive, multilayer films) and stretchable poly(dimethylsiloxane) (PDMS) substrates (enabling stretchable electronics). Four-layer PEDOT:PSS films have an Rs of 46 Ω per square with 82% transmittance (at 550 nm). These films, deposited on a pre-strained PDMS substrate and buckled, are shown to be reversibly stretchable, with no change to Rs, during the course of over 5000 cycles of 0 to 10% strain. Using the multilayer PEDOT:PSS films as anodes, indium tin oxide (ITO)-free organic photovoltaics are prepared and shown to have power conversion efficiencies comparable to that of devices with ITO as the anode. These results show that these highly conductive PEDOT:PSS films can not only be used as transparent electrodes in novel devices (where ITO cannot be used), such as stretchable OPVs, but also have the potential to replace ITO in conventional devices.

Highly Conductive and Transparent PEDOT:PSS Films with a Fluorosurfactant for Stretchable and Flexible Transparent Electrodes

Printing sensors and electronics over flexible substrates are an area of significant interest due to low-cost fabrication and possibility of obtaining multifunctional electronics over large areas. Over the years, a number of printing technologies have been developed to pattern a wide range of electronic materials on diverse substrates. As further expansion of printed technologies is expected in future for sensors and electronics, it is opportune to review the common features, the complementarities, and the challenges associated with various printing technologies. This paper presents a comprehensive review of various printing technologies, commonly used substrates and electronic materials. Various solution/dry printing and contact/noncontact printing technologies have been assessed on the basis of technological, materials, and process-related developments in the field. Critical challenges in various printing techniques and potential research directions have been highlighted. Possibilities of merging various printing methodologies have been explored to extend the lab developed standalone systems to high-speed roll-to-roll production lines for system level integration.

https://cris.fbk.eu/bitstream/11582/300858/1/Technologies%20for%20Printing%20Sensors%20and%20Electronics%20Over%20Large%20Flexible%20Substrates-A%20Review.pdf

Technologies for Printing Sensors and Electronics Over Large Flexible Substrates: A Review

We report a simple and rapid method to prepare multifunctional free-standing single-walled carbon nanotube (SWCNT) films with variable thicknesses ranging from a submonolayer to a few micrometers having outstanding properties for a broad range of exceptionally performing devices. We have fabricated state-of-the-art key components from the same single component multifunctional SWCNT material for several high-impact application areas: high efficiency nanoparticle filters with a figure of merit of 147 Pa−1, transparent and conductive electrodes with a sheet resistance of 84 Ω/◻ and a transmittance of 90%, electrochemical sensors with extremely low detection limits below 100 nM, and polymer-free saturable absorbers for ultrafast femtosecond lasers. Furthermore, the films are demonstrated as the main components in gas flowmeters, gas heaters, and transparent thermoacoustic loudspeakers.

Multifunctional free-standing single-walled carbon nanotube films.

Gravure printing of conductive particulate polymer inks on flexible substrates

The gravure offset printing method was examined for the manufacture of thick-film conductors on alumina, using Ag based inks. In this research, a roller type gravure offset manufacturing process was developed to give conductor lines and spaces down to 20 μm, together with a low square resistance. Novel hydrocarbon resin based inks have been used and compared to traditional ethyl cellulose based inks normally used in thick-film technology. The inks had a high viscosity compared to graphical inks due to their high solid content, which was necessary to enable a high printed mass. Different printing parameters were studied and printed sample properties were statistically compared. The results show that the cross sectional area of the lines is the best correlating measured property to describe the quality of the printing. 100% of the ink was transferred from the blanket to the substrate after 30 seconds. Prints from ink containing 85 wt.% of silver with optimised parameters resulted in a square resistance of 5 mΩ/sq. for 300 μm wide and 17 μm thick lines produced from a single print. These promising results are important requirements for high throughput electronics manufacture.

Printing parameters and ink components affecting ultra-fine-line gravure-offset printing for electronics applications

Gravure offset printing of polymer inks for conductors

The gravure offset method has been developed toward an industrially viable printing technique for electronic circuitry. In order to obtain the optimum ink resin for printing lines of required thickness (>5 /spl mu/m) of narrow lines (down to 25 /spl mu/m), several ink resin systems have been assessed in previous studies by the authors. The best printed results were obtained with a novel ink using a hydrocarbon resin. This ink did not comply with the traditional ink transfer mechanism based on evaporation of the solvent, but with a postulated new "absorption mechanism.".

Marko Pudas

Papers

Multifunctional free-standing single-walled carbon nanotube films.

Gravure printing of conductive particulate polymer inks on flexible substrates

Printing parameters and ink components affecting ultra-fine-line gravure-offset printing for electronics applications

Gravure offset printing of polymer inks for conductors

The absorption ink transfer mechanism of gravure offset printing for electronic circuitry